Wonderware: Corporate Energy Management CEM. Dawid Sadie General Manager: Sales Wonderware Southern Africa

Transcription

1 Wonderware: Corporate Energy Management CEM Dawid Sadie General Manager: Sales Wonderware Southern Africa

2 If you Google? (The Oxford Dictionary) energy noun (pl. energies) 1 the strength and vitality required for sustained activity. 2 (energies) a person s physical and mental powers as applied to a particular activity. 3 power derived from physical or chemical resources to provide light and heat or to work machines. 4 Physics the property of matter and radiation which is manifest as a capacity to perform work. Power Gas = = Water Steam Air Chill

3 ARC Report Energy Management Driving value in industrial environments Benchmark KPI s established for measure Released April 2009 OEE Reduction in energy consumption Relative margin

4 Problem statements drove the CEM product Data collected for energy usage and demand is not related to operational events or business processes Allocation of energy cost to produced goods and services is not accurate or useful in understanding the true costs of goods sold Operators are not aware of the consequences of decisions that create excessive energy usage or demand

5 Operational events drive cost! Time Fixed Intervals Make Order #ABC123 Cool Occupied Building Clean Process Equipment (CIP)...Again... and Again Production Asset State Starting Producing Idle Producing.33 kwh.26 kwh.19 kwh

6 Translated to innovation Event-based Energy Data Collection Triggered by anything accessible from underlying System Platform Fixed or variable duration (Shift vs. Production order) Accumulated cost from multiple energy use points Power, Water, Gas, Steam, Air, Chill Applies the current rate for each energy stream A single interval or event can have multiple rate updates Displays running cost in real-time Event reports by event type, specific event, and over time Event Energy Intensity computed for each event occurrence And yes, we also do interval based energy data collection for when it makes sense!

7 Context transforms energy data to energy info Production Worker Energy Manager Controller/Accountant Corporate Energy Manager InTouch HMI Real-time view of energy usage Configuration of the application Information Server Run Pre-configured 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 Usage Context Energy Information Application for Corporate Energy Management Energy Usage Data Energy Metrics Energy Usage Work Request Rich Data Corporate KPI ERP/MES Asset Management CMMS Advanced Analysis and Simulation Automatic Direct to Meters (also wireless) Meters thru PLC/DCS RTU from remote sites Building Management System Utility Interval Readings Mobile IntelaTrac Mobile Data Collection

8 Benefits of Corporate Energy Management Application Hard Savings Reduce cost of energy per unit of output Conservatively 5% (Aberdeen) 14% (ARC) Avoid peak demand charges (DSM) Organisational Benefits Meet Corporate Sustainability Initiatives for energy reductions and resource management Enable an energy continuous improvement program with long-term sustainable results Select and deploy a standard solution across all plants and sites, regardless of automation platform Smart grid enable an operation. Prepare the operation to take advantage of Demand Response, Market Pricing

9 A Unique Approach to Energy Management Focus on the Economics of Energy Usage Combine with production output information to create robust and accurate Units/Energy KPIs Bags/KWh or BTU Liters treated water per bottle Compute actual cost based on rate tables for each resource type Relate cost to production and operation What is our energy cost to make this product? What did it cost to make that batch or order? Active Intelligence Set traps to detect energy waste (great for Green Teams) Inform those who need to know, now! Flexible Views of Information By Department, Production Area, Asset, Product 9

10 A Unique Approach to Energy Management Fast Deployment Install and configure in days, not weeks or months Instantly connect to existing meters on the network Collect meter readings from un-connected meters using IntelaTrac Deploy inexpensive wireless meters or wireless retrofits to older meters Add fixed meters as they are installed and operational Fast Results Pre-built reports for instant information Real-time HMI components enable cost experiments Like a petrol pump! 1 0

11 Energy Usage Consumption = X Rate = Money Spent (8750 KWh * 0.13 = $1, Time sliced (this hour, shift, day, week, month, period, quarter, year) Used for tabular reports or spreadsheets Demand = Can be trended to understand when energy is used Can be alarmed to avoid peak demand charges Can generate events to be reported with consumption

12 Application Components InTouch Real-time view of energy usage Information Server for usage reports Intelligence-EMI for KPIs CEM Objects System Platform 3.1 IAS Historian WIS CEM Energy Usage Database DAS- PLC DAS- Modbus DAS- BACnet PLC DCS Building Management System Meters for: Electric Power Compressed Air Steam Water Gas Chilled Medium BACnet LonWorks

13 Energy Key Performance Indicators Energy KPI Operations Management KPIs Information Wonderware Intelligence Software Energy Data Corporate Energy Management Application MES Data Manufacturing Execution Systems Process Data Historians, Alarm Logs CMMS Data LIMS Data Peer Systems LIMS, CMMS System Platform

14 The Meter Object Built Using new Object Toolkit Compiled, no scripts Version Controlled Same UI for configuration and runtime Unique Look Library of Common Meters Fast Configuration of basic measurements and advanced features Highly Functional, Easily Configured

15 Energy Event Configuration User Defined Energy Events Define Groups Define Energy Events Not Industry Specific Shifts- fixed time Operations- no fixed time Single Shot events Collect Data for Energy Events Energy Usage Other useful information

16 ArchestrA Symbols and Displays

17 And Reports Economic Information In June, for my Blow Mold Operation, did I Meet my energy budget? Accurately forecast the daily demand? Do better than the last 5 months? Have any alarms or warning?

18 Corporate Energy Management Increase awareness of energy consumption and demand Consumption = Amount used (like an odometer) Demand = Rate of use (like a speedometer) Reduce Energy Costs Energy is almost always a significant cost of mfg or processing Relate energy consumption /demand to line, area, SKU, etc. ( contextualize ) Fast time to value (in days, not weeks) Quick deployment (with integrated App Server meter and event objects) Out-of-box reports Integration to industry standard energy meters

19 Exhibition Hall: Pods and Training Wonderware CEM Pod... Manned by Neil Rudden Wonderware CEM training... Delivered by Nilen Bermal

20 Questions?

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