Real-Time Green: Corporate Energy Management Integrated with Environmental Monitoring Systems (EMS) and Building Management Systems (BMS)

Transcription

1 Digital Pharma & Life Sciences Conference 2011 Real-Time Green: Corporate Energy Management Integrated with Environmental Monitoring Systems (EMS) and Building Management Systems (BMS)

2 Key Markets Sales and Growth forecast USA Dimensions: $ Bn Growth: 3-5% Top 5 EU Dimensions: $ Bn Growth: 1-3% China Dimensions: $50-55 Bn Growth: 25-27% Rest of the World Dimensions: $ Bn Growth: 6-8% Japan Dimensions: $80-95 Bn Growth: 5-7% Global market Dimensions: $ Bn Growth: 5-7% Emerging Countries Dimensions: $ Bn Growth: 15-17% Slide 2 SOURCE: IMS Health, Market Prognosis, Oct 2010 Emerging: China, Brazil, Russia, Mexico, India, Turkey, South Korea

3 Time for Change Slide 3 Life Sciences and Invensys share the same business model moving from 'self centric, do it yourself to collaborative networking to meet stakeholder's requirements: to maximize the value they get for the money they spend to develop effective new medicines more economically, help patients manage their health and ensure that the products and services they provide really make a difference.

4 Evolution 1 Blockbuster age Slide 4

5 Evolution 2 Collaboration age Slide 5

6 Evolution 3 Ecosystem age Slide 6

7 Slide 7 Challenges

8 Typical Energy Consumption Breakdown The major energy cost factors in the pharmaceutical facilities are: 10% Lighting 65% HVAC 25% Process Slide 8 Source: Energy efficiency improvement and cost saving opportunities for pharmaceutical industries. LBNL, 2008

9 Energy Consumption by Sector Offices Warehouses 5% 10% 15% Secondary 35% Bulk R&D 30% 5% Misc Slide 9 Source: Energy efficiency improvement and cost saving opportunities for pharmaceutical industries. LBNL, 2008

10 Integrated Solutions Corporate storage ERP/MES Asset Management Adv Analysis & Simulation Corporate KPI Contact less Software Marshalling Energy Informations Recovery Point Objective=0 EMS BMS HVAC Fire Access Monitor (not crit) Light Lifts Internal Contest External Contest Critical Sensors (wired or wireless) EMS critical data Video Mobile Energy Usage Data EMS Application with peace-of-mind Validation FMS Application embedding Good Eng Practices CEM Application Corporate Energy Management Slide 10 Source: ISPE Good Practice Guide: HVAC - Appendix 2, page 181 Position Paper: Use of BMS and EMS in Regulated Environments PEng Vol 25 No.5 Invensys proprietary

11 Slide 11 EMS: A Solution to Resolve Your Problem

12 What is the cost to my company? Cost of Data Loss The cost of a Data Loss Event is directly related to the value of the data and length of time that it is needed, but unavailable. Consider: The cost of continuing without the data The cost of recreating the data The cost of notifying users in the event of a compromise Banking Pharmaceuticals Retail Insurance Information Technology Financial Institutions Manufacturing Telecommunication Energy 280$ Cost of Data Loss per second Slide 12 0,0 1,0 2,0 3,0 Source: IT Performance Engineering & Measurement Strategies: Quantifying Performance Loss, Meta Group, Oct 2000

13 EMS: Main features Invensys EMS solutions are simple and affordable Recovery Point Objective=0 Critical Sensors (wired or wireless) Dedicated GAMP Cat. 3 EMS block Store&Forward to secure data integrity Flexible architectures are available. Benefits Isolated, high precision, stable sensors inputs. IO modules are hot swappable. Wireless/digital sensors are supported Configuration block with build-in features to manage parameterization, alarm priorities and delays. Mode: auto, man, maintenance Calibration blocks for easy to operate Fully redundant for High Availability Tamperproof multi level Store & Forward HMI interface based on Objects. Reusable, easy to change and to validate Data stored on an SQL database, with timestamp, powerful reporting Open communications. OPC, Secure ODBC, WEB support. Configuration completely GAMP5 Category 3 and 4. No sequences are required at all. FW&SW in one swappable memory module. Fully 21 CFR Part11 Slide 13

14 EMS: Store & Forward, what is it for? When system communications are lost...data will not be stored... May you try with interpolation?.. NEVER, reality cannot be invented! Slide 14

15 Slide 15 To ensure the availability and the integrity of Store & Forward Behaviour all critical measures

16 Software Marshalling GAMP Cat1 LIN protocol is used to move data from donor to receiver. DONOR EMS EMS BMS EMS critical data RECEIVER BMS Invest effort and money where necessary. Benefits Less validation effort. No need for sensor duplication or wiring. No double indication. No errors. No offsets. No linearization issues. Less maintenance. Integrated diagnostic and alarm management, including calibration. EMS sensor parameters are all fully available to the receiver BMS. One way communication to achieve proper EMS/BMS segregation. Network independent. EMS could be made fully redundant to guarantee High Availability. Easier commissioning with reduced time to market. Make EMS more robust providing more and better quality data to the BMS. Slide 16 Source: ISPE Good Practice Guide: HVAC Appendix 2, page 181

17 FMS: Main Features Leverage open connectivity and advanced graphics Slide 17 HVAC Fire Access Monitor (not crit) Video Light Mobile Lifts Simplify maintenance with remote deployment Quick start with symbol libraries Collect and analyze data from new and existing systems Monitor and control from anywhere Benefits Connectivity to new and existing building automation systems through open standards such as BACnet, Lon Works, MODBUS and OPC Easy integration with multiple equipment manufacturers including HVAC, fire, life safety, security, personnel access, energy management, lighting, elevators, emergency generation, sprinklers and refrigeration Uses Foxboro PAC for redudant, cost effective solutions integrated with our EMS systems Increase BMS performances and HMI response time Flexible development environment offering advanced remote application, maintenance and reporting capabilities Robust, IT-based security model Reduced operator training requirements Achieve environmental sustainability through compliance with industry, regulatory and green initiatives

18 FMS: Architecture InTouch or TS Operator Clients Information Clients Domain Controller Active Directory Historian Server TIER 2 Typical Building Automation System: Ethernet Data Network (with Firewall) TS Data Server Redundant Control Mesh Ethernet Network Galaxy Modbus RTU / ModbusTCP Info Server BACNET LonWork Historian Server TIER 1 Field Devices temperature, humidity, motion, vibration, energy, pressure, sensors, valves, actuators, relays, Smart Devices motor drives, room sensors, meters, thermostats, intelligent components, Controllers room, air handler, fan coil, chiller, boiler, cooling towers, motor control centers, Systems lighting, electrical/energy, fire/life safety, security/personnel access, maintenance, Modbus RTU Slide 18

19 Slide 19 FMS: HVAC Library Objects

20 CEM: Main Features Invensys CEM talks about real-time money. Slide 20 Internal Contest External Contest Energy Informations Energy Usage Data Benefits Combine with production output information to create robust and accurate Units/Energy KPIs Compute actual cost based on rate tables for each resource type Relate cost to production and operation Set traps to detect energy waste (great for Green Teams) Inform those who need to know, now! Groups data as required: by Department, Production Area, Asset, Product Active intelligence Focus on the Economics of Energy usage Flexible view of information Account for All Energy Types - Points of Energy Usage Account for Self Generation of Power

21 But I have already optimized my operations Monitoring energy performance may also identify areas that are candidates for operational improvements and cost savings such as labor, chemicals, maintenance and disposal costs. It can also detect and alert to other issues. For example: A sudden unexplained increase in energy consumption may be an indication of: Equipment degradation Equipment failure An obstruction A problem in facility operations Slide 21

22 CEM: Architecture InTouch or TS Operator Clients Information Clients Domain Controller Active Directory Historian Server TIER 2 Ethernet Data Network (with Firewall) TS Data Server Galaxy Redundant Control Mesh Ethernet Network Modbus RTU / ModbusTCP Info Server BACNET LonWork Historian Server TIER 1 Fast deployment Install and configure in days, not weeks or months Instantly connect to existing meters on the network Collect meter readings from unconnected meters using IntelaTrac Deploy inexpensive wireless meters or wireless retrofits to older meters Add fixed meters as they are installed and operational Slide 22 Modbus RTU Fast results Pre-built reports for instant information Real-time HMI components enable cost experiments

23 CEM: to Measure What? Key concepts: Energy dispenser Energy event Energy intensity Slide 23

24 Concept: The Energy Dispenser Transaction Total Energy Units Dispensed Price per Unit Slide 24

25 Concept: Energy Event A Beginning An End A Duration Something uniquely identifies an event Things happen related to the event Slide 25

26 Thus Every time an energy event occurs, and you can get the results from the energy dispensers, you have the energy cost of the event. Slide 26

27 Concept: Events Happen! Time Fixed metering recorded intervals Make Order #AB4587 Cool Occupied Building Clean the Processing Equipment again and again Production asset state starting producing Idle!!!!! producing.33 kwh.26 kwh.19 kwh Slide 27

28 Concept: Real-time Energy Intensity Add units of output to energy events and get Intensity Example: A batch process ran for 79 minutes, consumed 352 KWh of electricity, and produced 5004 grams of product. Energy Intensity = 0.07 KWh/gram How does this compare to the last 23 times you made batches of this product? Slide 28

29 Slide 29

30 Energy Intensity is the Key Performance Indicator of the Future Slide 30 ANSI/MSE , ISO-50001

31 Context Transforms Energy Data to Energy Information Production Worker Energy Manager Controller/Accountant Corporate Energy Manager InTouch HMI - Real-time view of energy usage - Configuration of the application Web Portal - Run Preconfigured reports - Intelligence- EMI for Operations Internal Context - Operational Events from automation and MES - Asset State from automation Order, Batch, SKU External Context - Weather- Current, Forecast - Utility Rates - Demand Response Signals from Grid Slide 31 Usage Context Automatic Direct to Meters (also wireless) Meters thru PLC/DCS RTU from remote sites Building Management System Utility Interval Readings Energy Information CEM Corporate Energy Management Application Energy Usage Data Mobile IntelaTrac Mobile Data Collection Energy Metrics Energy Usage Work Request Rich Data Corporate KPI ERP/MES Asset Management CMMS Advanced Analysis and Simulation

32 CEM Highlights: The Meter Object Built Using new Object Toolkit Compiled, no scripts Version Controlled Unique Look and Workflow Library of Common Meters Fast Configuration of basic measurements and advanced features Slide 32

33 CEM Highlights: Energy Event Configuration User Defined Energy Events Collect data associated to event Add context Examples: Current Flow Product Count Set-Points Logged on Operator Temperature Production Rate Slide 33

34 Slide 34 CEM Highlights: Intelligence

35 Why Corporate Energy Management? CEM could provide the intelligence you will require to cope with: Slide 35 Energy prices shift Batch flexibility Experienced people turnaround An undetected pump failure Lab ventilation seasonal tuning Staff behavior Ducts leakages Adjustable speed drivers HVAC chillers efficiency Good operating practices

36 Thank you!