2 4b energy - psi metals
TRANSCRIPT
© PSI Metals 2011Slide 2
PSI: Process Control and Information Systems
PSI is the leading German supplierof control system software solutions
for energy utilities and industry.
© PSI Metals 2011Slide 4
PSImetals Energy: general tasks and aims
Collect and display data of power producing and power consuming plants
Control of energy consumption and production
Forecast for power consumption and production for different time periods
Integration of production scheduling and real time production events
Avoiding the violation of contract limits
Optimization of steel production respecting energy costs.
© PSI Metals 2011Slide 5
PSImetals Energy: Energy Management System
Important features:Steel-specific:A standard system tailored to the needs of the steel industry.
Proven and tested: High stability, available to use in 7*24h operations.
Flexible:Highly parametrizable and adaptable to changing requirements at any time.
Learning:Permanent, automatic optimization thanks to adaptive algorithms.
Modular:Modular system architecture enables integration of further media without any problems.
© PSI Metals 2011Slide 6
PSImetals Energy: Energy Management System
Components
• EBF – Basic functions
• ECF – Electrical energy
• PDC – Load management
• GCF – Gas and other media
© PSI Metals 2011Slide 7
PSImetals Energy: System Components
EBF Energy Basic Functions
PSIintegration
ECFElectrical Energy
Consumption Forecast
PDCPower Demand
Control
GCFGas Consumption
Forecast
© PSI Metals 2011Slide 8
PSImetals Energy at ArcelorMittal Eisenhüttenstadt
History of Energy cooperationbetween AM Eisenhüttenstadt and PSI
Requirement specification for Load Management System (LMS) in 2000
Implementation and going live of Load Management System in 2001
Requirement specification for Gas Management System in 2002
Implementation and going live of Gas Management System (GMS) in 2003/2004, close partnership with BFI (VDEH)
Further enhancements in 2005 and 2006
© PSI Metals 2011Slide 9
PSImetals Energy at ArcelorMittal Eisenhüttenstadt
Realized interfaces with
MES system for planning and scheduling
Electricity counting system for measurements
Steel mill control system (LF integration)
HRM control system via MES
CRM control system via MES
Designed computer interface to
Power supply company
© PSI Metals 2011Slide 10
PSImetals Energy: EBF - Energy Basic Functions
EBF Energy Basic Functions
PSIintegration
ECFElectrical Energy
Consumption Forecast
PDCPower Demand
Control
GCFGas Consumption
Forecast
© PSI Metals 2011Slide 11
PSImetals Energy: EBF - Energy Basic Functions
Collecting Data - Creating TransparencyMeasured-value acquisition and compression
Plausibility checks for all data, Marking / highlighting of invalid data
Automatic measured-value correctionMarking / highlighting of corrected measured values,the original measured values are retained
Check of overall measurements vs. the sum of individual measurements
Definition of software measuring points
Compression of momentary measured values gathered, for example, at a second‘s interval
Archiving of historical data:online database, archive database and reproduction database
Plant downtime scheduling and planning
Contract updating
© PSI Metals 2011Slide 13
Managing supply contractsVariable accounting / billing interval
Several supply contracts per accounting / billing interval
Different supply volumes per accounting / billing interval and supply contract
Contracts for the supply of electrical energy:
Energy costs for the electrical energy actually consumed
Costs for the provision of power station capacity (provision of standard energy)
Penalties for upper (or lower, if applicable) deviations from the agreed power limits
PSImetals Energy: EBF - Energy Basic Functions
© PSI Metals 2011Slide 14
PSImetals Energy: Supply contracts
Screen showing detailsof a specific energy contract.
PSImetals Energy: EBF - Energy Basic Functions
© PSI Metals 2011Slide 15
Integration of new plants
and worksPSImetals Energy manages works and, within the works, individual plants
Integration of new works orplants is possible withoutprogramming
General rule:All controlling parametersof the system are stored asvariables which can bechanged by the user
PSImetals Energy: EBF - Energy Basic Functions
© PSI Metals 2011Slide 16
Benefits of the basic functions
Acquisition of all measured values –
therefore reproducibility of consumption possible
Assignment of consumption to plant and/or works –
therefore assignment of costs is possible
Correlation of the actual consumption to energy contracts becomes evident –
therefore improved transparency
Data archiving – enabling future analyses even of parameters which are
subject to low change rates
PSImetals Energy: EBF - Energy Basic Functions
© PSI Metals 2011Slide 17
PSImetals Energy at ArcelorMittal Eisenhüttenstadt
5 main consumers:
• REW = hot metal plant with 2 blast furnaces
• KSW = steel mill with 2 BOF, 1 LF
• WWW = hot rolling mill
• KWW = cold rolling mill
• the town Eisenhüttenstadt
About 20 important consumers with single measured values
A power station with 5 steam boilers for blast furnace gas, converter gas, natural gas and 1 natural gas turbine
Power supply contract
© PSI Metals 2011Slide 18
LMS at ArcelorMittal Eisenhüttenstadt
Five main plants are divided into important single consumers
Planned downtimes are integrated via interface with planning and scheduling system and MES,combined with automatic detection of downtimes
Interface with measurement systems.
LMS gets measured values every 5 seconds for each consumer.
Measured values are consolidated and stored into the LMS system.
Consolidated values are stored up to 10 years in special archiving database.
Integrated breakdown recognition module using measured values
© PSI Metals 2011Slide 19
EBF Energy Basic Functions
PSIintegration
ECFElectrical Power
Consumption Forecast
PDCPower Demand
Control
GCFGas Consumption
Forecast
PSImetals Energy: ECF - Energy Consumption Forecast
© PSI Metals 2011Slide 20
PSImetals Energy: ECF - Energy Consumption Forecast
Looking to the future
Different forecasting methods for different applications included
Free assignment of one or more forecasting methods to the plants
Automatic weighting of the different forecasting methods
Import of plan data and integration thereof into forecasts
Automatic unplanned downtime detection
Preparation of a time schedule for the utility company
Evaluation of the forecast precision
Internal power generation, if any, by the consumer is considered
© PSI Metals 2011Slide 21
Hot rolling mill
Cold rolling mill
Utility Power station
Small loads
Internally produced gas (blast furnace gas)
Consumption of electrical energyExternally supplied electrical energyElectrical energy fed back into the grid
Externally supplied gas (natural gas)
Gas supply company Steelworks
Blast furnace
Baseload
None
EAF, LF
Rolling stands
Rolling stands
City load curveSwitchable loads
PSImetals Energy: ECF - Energy Consumption Forecast
© PSI Metals 2011Slide 22
Forecasting methods
Forecast on the basis of production planning data, production forecast
• Forecast on the basis of a (constant or variable) baseload, baseloadforecast
• Forecast based on present measured values,measured-value forecast
Integration of plant-specific forecasting models, for example, for electric furnaces, taking the heat sequence into consideration, model forecast
Total forecast with adaptive weighting
PSImetals Energy: ECF - Energy Consumption Forecast
© PSI Metals 2011Slide 23
PSImetals Energy: Forecast
Forecast based onproduction plans andmaterial parameters
Forecast based on shift plans
Forecast based on current measurements
Forecast based on load patternrecognition
Summarizationto
total forecastValuation
© PSI Metals 2011Slide 24
Forecasting periods
The forecasts are re-calculated for:
the present interval (15 minutes): automatically every 30 seconds
the next 8 intervals (2 hours): automatically every 30 seconds
the next 144 intervals (36 hours): automatically every 15 minutes
the next month: must be explicitly triggered by an authorized user
PSImetals Energy: ECF - Energy Consumption Forecast
© PSI Metals 2011Slide 26
PSImetals Energy: ECF - Energy Consumption Forecast
Forecasting precision
Typical values:
15-minute interval: 2% to 3%
2-hour interval: 3% to 6%
36-hour interval: approx. 8%
The forecasting precision is automatically calculated in the ECF and stored in the database.
© PSI Metals 2011Slide 27
Benefits of the forecasting function
Different forecast calculations
• therefore reliable consumption monitoring possible
Comparison of actual values with the power supply contracts
• therefore a possibility to reduce the price per kilowatt, avoidance of
penalties due to limit-value violations
Preparation of timetables
• therefore better coordination with the utility company is possible
PSImetals Energy: ECF - Energy Consumption Forecast
© PSI Metals 2011Slide 28
EBF Energy Basic Functions
PSIintegration
ECFElectrical Power
Consumption Forecast
PDCPower Demand
Control
GCFGas Consumption
Forecast
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 29
Load management functions and goals
The agreed maximum value may not be exceeded under any circumstances.
Monitoring and control of switchable loads for the safe avoidance of load peaks
Minimum interference with production, and hence avoidance of intervention and shutting down of plants/units whenever possible
Controlling the energy consumption by electric arc furnaces and ladle furnaces by:
• reducing power consumption (changing the transformer voltage)
• complete shut-down, if necessary
Disabling the activation of non-switchable loads
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 30
Benefits of load managementReliable adherence to the lowest maximum value possible
The energy available during an interval is utilized to the maximum extent possible
Minimum interference with production because the number of operator interventions is reduced
Power reduction and/or shutting down is avoided as long as possible
Priority-controlled energy distribution, depending on the progress of production in the case of several switchable loads
Creating transparency
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 31
Control principle
Calculation of setpoints and limit values
Filter
PGS
_
POS
Priorities
Powercontrol
PO
PB
PG
TW
G< W
V
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 32
*) Pre-set by an energymanagement system, if applicable
Setpointvoltage level
Setpoint of maximum value *)Actual value of baseload
Actual valuespower, energy
Load management
Connection to aprocess management system
Operation diagram
Default power
Energy demand(desired power, energy)
Process controlPSImetals
Production&Quality
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 33
PSImetals: Energy und Online Heat Scheduling
Visualizing the process flow
In-time planning and production control
Forecast of energy consumption
Allows simple solving of conflicts
Home - Index - PSImetals PES: Online Scheduling
© PSI Metals 2011Slide 34
Benefits of the power demand control system
Safe avoidance of exceeding power limits
Effective utilization of the energy quota made available
Increased productivity by minimizing shut-down time
Long-time archiving of the relevant data and hence:
• Creation of more transparency of the loads and processes concerned
• Possibilities for analyzing consumption patterns and hence
• Possibility to optimize power supply contracts
PSImetals Energy: PDC - Power Demand Control
© PSI Metals 2011Slide 35
PSImetals Energy - Smart Grid for Metals
Smart grid is a type of elctrical grid which attempts to predict and intelligently respond to the behaviour and actions of all electric power suppliers and consumers connected to it - in order to efficiently deliver reliable, economic, and sustainable electricity services.
Production planning
Contract- and procurement management
Production execution Process- control
and models
© PSI Metals 2011Slide 36
PSImarket
Procurement Plan,Scenarios
Energy Market
Procurementand Proprietary Trading
Historical andPlanned Salesand Profiles
Market Prices,Products
IntegratedRisk- and Portfolio Management
HedgedProcurementCosts
Sales
© PSI Metals 2011Slide 37
Reacting to buying conditions
Paradigm change cause of regenerative energy production
Today: “energy production follows consumption”
Tomorrow:“consumption follows energy production”
Quelle: DER SPIEGEL Nr. 38 2010
37
Unsettled powerPower consumption and wind power in Germany, Dec. 2009
Power consumption
Wind power
© PSI Metals 2011Slide 38
Optimizing the portfolio
Analyse, Information, Recommendations
PSImetals Energy in futureforecast of renewable
energy production
forecast of energy-intensive consumers
Optimized production
© PSI Metals 2011Slide 39
PSImetals Energy – Overall Optimization
Planning and Scheduling
Energy Forecast
Optimized Schedule and Line Sequences
Optimized Energy Costs and Production Results
Real Time Event Handling
Cost Evaluation
Home - Index - PSImetals EMS – Energiekosten über den Produktionsplan optimieren
© PSI Metals 2011Slide 40
PSImetals Energy together with Planning
Orders
Energy
Portfolio and demand
Rules, technicalconstraints & standard practices
Inventories levels
© PSI Metals 2011Slide 43
Contact
Peter Bergfort
Sales Manager
PSI Metals GmbHHeinrichstraße 83-85
40239 DüsseldorfGermany
phone:+49/211/602 19-588mobile:+49/172/23 23 482
fax:+49/211/602 19-240
email: [email protected]
FOTO Franz
www.psimetals.com
© PSI Metals 2011Slide 44
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