sustainable production solutions in industrial energy ... · pdf fileall of these solutions...

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Sustainable Production Solutions in Industrial Energy Management

Terry Gebert Vice President and General Manager Global Solutions

Rockwell Automation At A Glance

• Annual Sales: $5.7 billion • World Headquarters: Milwaukee, Wisconsin, USA • Trading Symbol: ROK • Employees: ~ 21,000 • Serving customers in 80+ countries

Leading global provider of industrial automation control and information solutions

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2

Sustainable Production Defined

Source: US Energy Information Agency: http://www.eia.doe.gov/oiaf/ieo/ieoenduse.html

Sustainable Production refers to processes and technologies that use minimal amounts of energy and resources, create minimal amounts of waste, and leave future production capabilities unhindered. It can also address workplace safety, product safety and reliability, and reuse of waste products in the reverse supply chain.

Our approach to sustainable production makes our clients’ operations cleaner, safer and more efficient.


Sustainable Production Solutions

Energy Environment Safety Energy Management Emissions and Environment Product Safety

Demand Management *Demand Response* Measurement * Trending * Emergency Load Shedding * Power Quality

Monitoring * Controlled Shut Down * Load Profiling * Load Curtailment * Electrical Distribution System Monitoring * Power Factor and Harmonic Control * Cost Allocation *

Plant Wide Energy Optimization * Facilities Energy Profiling * Production Energy Profiling

Flue Gas Desulfurization * Diesel Electric Tug Propulsion * EPA-Compliant Coke Batteries * Water/Wastewater *

Environmental Systems Design * Continuous Emissions Monitoring * Effluent Monitoring * Predictive Emissions

Monitoring * Real Time Environmental Management

Track and Trace * Central Plant Control * Centralized Scheduling * Material Accountability * ePedigree *

Manufacturing Execution Systems * Electronic Batch Record (EBR/DHR) * Corrective Action, Preventative

Action *

Industrial Utilities Resource Optimization Machine/Worker Safety Boiler Control * Chiller Control * Compressor Control *

Generator Control System * Industrial HVAC * Emissions Compliance Reporting * Wastewater Reporting * Boiler

Optimization * Chiller Plant Optimization * Ammonia Compressor Plant Optimization*Advanced Process Control

of Utility Units * Emissions Monitoring

Oil Pumpjack Optimization * Newspaper Print Cut Downs * Burner Management/Combustion Control * Production

Management * Metallurgical Accounting * Line Performance * Capacity & Product Mix Management *

Schedule Optimization * Equipment Optimization

Wind Up and Let Off * Press Controls * Risk Assessment Services * Asset Management * Intelligent Motor Control *

Control Interlocking * Ship Control * Safety Networks * Machine Guarding

Alternative Energy Production Resource Recovery Process Safety Biodiesel and Ethanol Control Systems * Solar Control Systems *Cogeneration Control Systems* Wind Power Control Systems *Geothermal Power Control Systems*

Distillation for Algae Extraction

Solvent Recovery Units * Scrap Reduction Solutions * Emergency Shut Down Systems * Burner Management * Blow Out Prevention * Hazardous Operations Studies *

Condition Monitoring & Protection * Safety & Critical Control * Statistical Process Control * Turbo Machinery

Control * Ballast Control * Fault Tolerant Safety Solutions


Rockwell Automation Energy Scope

Emerging Market – Alternative / Renewable Power Generation

Combined Cycle Wind (turbine control, network infrastructure, SCADA)

Solar (SCADA, positioning & control, grid tie inverters)

Geothermal (turbine, generators, well pad control, steam systems)

Biomass/Waste (thermo-catalytic conversion)

Industrial Demand Side Energy Management

Energy consulting, audits, PEMS, simulation, optimization, demand management, demand response, energy recovery

Transmission & Distribution/ Smart Grid*

substation automation & integration program

Traditional Generation Fossil powered units (fuel handling, boilers Hydro (turbine control, gate & reservoir control, SCADA) Gas Turbines (anxillary systems, balance of plant)

We provide tools, technology and solutions to support transmission, distribution, consumption and recovery.

Adapted from de:Datei:Stromversorgung.png/Stefan Riepl (Quark48), Hintergrund weiss gefaerbt von Leon


Optimization Starts with Information

The effective use of plant-floor data collected from automation systems provides real-time intelligence necessary for the optimal use of resources – including energy .

Production Facility

Business Enterprise Systems


All of these solutions collect data and solve problems individually – the true business value is in pulling it all together.

Rockwell Automation Sustainable Production Solutions

Production Facility

Business Enterprise Systems

Mechanical Efficiency

Burner Management

Combustion Control &

Optimization

Material Accountability

Effluent Monitoring

Solvent Recovery

Production Management

Electrical & Machine Safety Process Safety

and Control

Energy Control

Energy Visualization

Energy Optimization

Asset Management

Production Performance

Process Optimization

Environmental Systems Design

Continuous Emissions Monitoring

Real-Time Environmental Management

Model Predictive Control

Predictive Demand

Management

Material Handling

ePedigree


Sustainable Production Solutions in Energy

Business Intelligence •Facility Energy Profiling •Inventory Management

•Production Energy Profiling •Performance Management

•Recipe Management •Asset Management

•Capacity/Product Mix Management

Regulatory Compliance •Material Accountability •Corrective Action, Preventative Action

•Traceability/Genealogy •Environmental Monitoring

•Electronic Record (EBR/DHR) •Facilities Energy Reporting

•Emissions Monitoring •Quality Management

Operational Efficiency •Production Optimization •Model Predictive Control

•Energy Optimization •Production KPI Profiling (e.g.OEE)

•Equipment Optimization •Schedule Optimization

•Statistical Process Control

Industrial Information Management Energy Visualization

•Plant Electrical Infrastructure Status •Power Quality

•Distribution System Monitoring •Facility Energy Profiling

•Measurement and Targeting •Process Energy Profiling

Energy Control •Emergency Load Shedding •Peak Shaving

•Demand Management •Supervisory Generator Control

•Emergency Generation •Supervisory Cogeneration Control

•Load Curtailment

Energy Optimization •Thermal Plant Optimization •Mechanical Efficiency

•Chiller Plant Optimization •Energy Scheduling

•Ammonia Plant Optimization •Supply/Demand Matching

•Industrial HVAC

Industrial Energy Management


Solution: Facility Energy Profiling

• Automated Metering Infrastructure monitors energy resources – Water, Air, Gas, Electricity and Steam - in relation to equipment usage and environment conditions • Collects data and stores it in an energy historian • Presents data for further analysis

– KPIs / Dashboards (Operational Effectiveness) – Reports/trending (Engineering Analysis)

4500 KW base load costs $1.2 M USD annually --Seems High for a

mixed use facility (Office and Limited Manufacturing)

By knowing the necessary demand, energy supply can be determined by price from

the utility – purchase or generate, buy or sell.

Monitor the consumption of energy by equipment to establish economic cost profiles of compressors

motors, fans


Solution: Production Energy Profiling

• Metering monitors energy consumption and quality from the point of use in a production process (KW/h per product, per line) • Collects data to establish process baselines, ‘golden batch’ • Establishes equipment performance baselines for energy and asset management • Presents production data against established process standards for deviation analysis

RSEM

5 batches consumed 38% of the energy to manufacture this product on this day. May indicate a quality issue such as equipment out of calibration.

Base load constant 24/7 but increases as temperature exceeds 30 deg F - May

indicate a cooling capacity issue on a product line.


Solution: Emergency Load Shedding

• Prevents critical losses due to unforeseen losses of power • Applies to sites with generation or multiple utility sources • Protects generators from dangerous, damaging overloads • Maintains critical loads during outages • Optimizes sources and critical loads • Eliminates costs associated damaged equipment • Pays for itself in one or two outages


Solution: Equipment Optimization Solutions

Production KPIs (e.g. OEE) • Optimizes resource utilization

• Maximizes resource loading • Minimizes changeovers

• Improves energy usage • Sets standards of energy efficiency, track lost energy

• Minimizes wasted energy

• Improves production efficiency • Eliminates scrap

• Improves product quality

Asset Management and Governance • Optimizes maintenance and plant operations to

improve resource availability • Provides secure & auditable access to Plant Automation • Provides backup/recovery of operating asset configurations • Manages automation asset configuration files • Configures process instruments • Manages device calibrations


Solution: Plant Optimization

Thermal/Chiller Plant Optimization • Applies to boilers, chillers & ammonia compressors • Interfaces new & existing machines to:

• Optimize energy consumption • Reduce power demand • Improve overall efficiency

• Improves efficiency by optimal equipment dispatch based on utility supply/demand

• Reduces cost through: • Chilled water reset • VFDs on primary & secondary pumps, cooling tower fans,

condenser water pumps • Wire to water optimal dispatch of equipment based on ODAT • Suction Header Pressure dispatch of machines

Industrial HVAC - Air Handler Controls • Replaces old and outdated HVAC

control systems with updated controls and mechanical systems

• Reduces energy costs by: • Minimizing air changes

• Instituting economizer control • Scheduling air handlers


Solution: Supervisory Co-generation Control

Co-Generation-Renewable Sources • Applies to Gas Turbines, Diesel

Generators, Wind and Photovoltaic generated power

• Provides alternate / reliable source of energy that is potentially more cost effective than conventional means.

• Turbine / Chiller combinations • Newer more efficient equipment replaces

older less dynamic or adaptive systems

• Provides the means to meet the exacting demands of the facility without incurring large fluctuations in utility billing

Demand Management – Load Curtailment • Provides dynamic balancing of supply versus

demand based on environmental conditions • Supports grid wide stability

• Reduces costs associated with rebate programs


Client Request

• Integrate process data from 2 mixed use facilities • Identify and improve repeatable cycles in their electrical

and mechanical systems • Maintain reliable supply of power to entire campus

environment, supporting LEED initiatives in their new building construction.

• Areas to be explored and supported: • Solar ™gas turbines for co-generation and heat • Power distribution control and monitoring • Building and plant HVAC systems • Chillers, boilers, pumps usage and scheduling • Data center Power and HVAC supply

“P”Campus


Rockwell Automation Control Solution

• Enables closed-loop energy management from a single control point

• Provides plant-wide electrical and mechanical load profile and usage footprint

• Evaluates equipment efficiencies to determine optimal control through process modeling, detailed monitoring and a control from a centralized system

• Maintains the operating criteria of the connected components that monitor and control the entire electrical / HVAC supply and distribution system

• Manages demand and balanced equipment use through scheduling and rotation of components

• Utilizes 500 kW Photovoltaic System as substantial renewable energy source • Provides a dedicated emergency chilled water system and automated re-start of central plant operations


Results

• Combined Power and Heat Systems: • Provides 7/24 Power Generation and Cooling • Provides 90% of electricity requirements • Saves 6,172 tons/yr in greenhouse gas emissions

(CO2), equal to removing the annual carbon emissions of 1,052 cars.

• Photovoltaic arrays : • Saves over $125,000/yr in electric cost • Avoids 49 tons of greenhouse gas emissions/yr -

equal to removing the annual carbon emissions of 136 homes per year.

• Energy Demand Response Activation System enabled when ISO Stage Alerts are in effect

Benefits: Effective use of equipment, continuous monitoring and reporting on critical system functions

LEED Gold Certified “W Campus” –1 Million ft2


Enterprise Energy Optimization

• Facility Energy Monitoring and Demand Management • Plant Floor Energy Monitoring, Management and Control

• Energy (WAGES) on the Production BOM • Production Modeling & Optimization • Production Demand Management • Demand Response to Regulation

Rockwell Automation’s approach to aligning energy consumption with energy demand Customer benefits realized to date:

Potential future solutions:


Thank you

Terry Gebert Vice President and General Manager Global Solutions


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