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WW OPS-6 Transform Energy Data into Operational Information with Wonderware Corporate Energy Management. Bill Schiel Director- Global Business Development Rudy Engert Business Development Manager – CEM & W/WW Christian-Marc Pouyez Product Manager – Intelligence & CEM. Agenda.

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Bill schiel director global business development rudy engert

WW OPS-6 Transform Energy Data into Operational Information with Wonderware Corporate Energy Management

Bill Schiel

Director- Global Business Development

Rudy Engert

Business Development Manager – CEM & W/WW

Christian-Marc Pouyez

Product Manager – Intelligence & CEM


Agenda

Agenda

  • CEM problem statement & definition, opportunity

  • CEM product description

    • Integration with ArchestrA System Platform

  • Demo

  • CEM, Intelligence, Workflow, Reports,…

  • Business cases

  • Roadmap


Definition of corporate energy management

Definition Of Corporate Energy Management

  • What is CEM?

  • "CEM" refers to sets of actions that move accountability for energy outcomes to upper levels of the firm. With CEM, energy is no longer the sole responsibility of plant managers and engineers; in fact, CEM programs are designed to involve many areas of business activity, such as accounting, marketing, and others that were not traditionally concerned with energy. Bringing corporate-level attention and management into the picture helps to ensure enterprise-wide opportunities are explored.

From US Dept of Energy: http://www1.eere.energy.gov/industry/bestpractices/corporate_energy.html


Cem is an ems designed for manufacturing

CEM is an *EMS Designed for Manufacturing

Specified by the Invensys voting member of ISO 50001 US TAG

A clean-sheet design, a configurable application

Intended for use by manufacturing and heavy industrial operations, but also applicable to any energy consuming enterprise

Bridges energy use data and manufacturing operational data

The only product on the market that produces real-time Energy Performance Indicators for Intensity

Closes the loop on information through an integrated workflow component that drives accountability

* EMS is Energy Management System


Cem and enterprise control for energy

CEM and Enterprise Control for Energy

  • Approach:

    • Use CEM, SP, EMI, AWF, and other components for a total solution

    • Provide Local level detailed information for day-to-day operations

    • Corporate level reports and analysis for weekly, monthly use

    • Energy Consumption used for Activity Based Accounting for Energy-ABC4E

    • Energy Consumption fed to Green House Gas and resource reporting

  • Big Picture Concept:

  • Solve a corporations energy management initiative for ALL energy consuming assets:

    • Factories and Plants

    • Research centers

    • Distribution Centers and Warehouses

    • Offices


Energy management is a straight forward concept

Energy Management is a Straight-Forward Concept

  • Why do manufacturers and industry have energy management initiatives?

  • Financial Benefits

    • Spend less: Reduce Energy-Spend as an indirect cost

    • Use less: Reduce Energy Cost in COGS (materials+labor+energy)

    • Avoid unplanned cost: energy-use penalties (demand charges, surcharges)

    • Resource Availability: Plan for, and respond to, unreliable energy supply (brown-outs)

  • Corporate Responsibility

    • Triple Bottom Line: Profit, People, Planet

    • Demanded by their customers (standards eg: Walmart)

    • Demanded by their governments (Regulations)


  • What is return on investment

    What is Return on Investment?

    Example for Electricity

    • What CEM can do:

      • Decrease consumption spend 10-30%

        • 10% of $240,000 = $24,000 year

        • 30% of $240,000 = $72,000

      • Avoid Surcharges

        • ½ avoided = $25,000

      • Total Decrease of $49,000 to $97,000 year

    • We Need to know:

      • Annual and Monthly Consumption Spend on Energy

        • Example: Annual $240,000, monthly average $20,000

      • Surcharges for excess total usage and demand penalties

        • Example: 10 charges per year, total $50,000

      • Total Annual Spend $260,000

    Investment is Software+Hardware+Services and will vary with EVERY project

    based on the application and the state of the energy metering infrastructure


    Key concept the journey

    Key Concept: The Journey


    Ad hoc

    The “Low Hanging Fruit” is addressed

    Energy efficient lighting, occupancy sensors

    Variable speed drives installed

    Low flow water fixtures installed

    Spot check and manual reporting of energy/water usage monthly or weekly

    Challenges

    Did it work?

    Is it still working? “Low hanging fruit grows back”

    Are there unintended consequences?

    What if Roberto leaves?

    Ad Hoc


    Evidence

    Evidence


    Awareness

    The organization learns about energy use and adapts

    Sub-metering gives more granular usage

    Experiments occur… what if we did this..? Kaizen in action!

    Investments are made knowing ROI can be determined

    Weekly, Daily, Shift reports become part of normal operations management

    Real-time notification of success, deviations, failures

    Challenges

    Demand for more meaningful data, related to what people are responsible for

    Knowing deviations and failures is good, but can we prevent them?

    Are there unintended consequences?

    Awareness


    Managed

    Energy Management is an organizational competency

    Everyone knows how energy usage and deviation effect financial performance

    Energy is managed as a variable cost and used by ERP for planning

    The benefits of the energy management are sustained year after year

    Automation is in place to prevent deviations

    Smart Grid becomes a competitive advantage, bring it on!

    Challenges

    Change

    Continuous improvement

    Managed


    Cem product description

    CEM Product Description


    Context transforms energy data to energy information

    Context Transforms Energy Data to Energy Information

    Production Worker

    Energy Manager

    Controller/Accountant

    Corporate

    Energy Manager

    • Web Portal

    • Run Pre-configured reports

    • Analytics, Trends

    • InTouch HMI

    • Real-time view of energy usage

    • Real-time KPIs

    Intelligence- EMI for Operations

    Energy

    Information

    Internal Context

    • Operational Events from automation and MES

    • Asset State from automation

    • Order, Batch, SKU

    Corporate KPI

    Energy Metrics

    ERP/MES

    Corporate

    Energy

    Management

    • Application

    • (CEM)

    Energy Usage

    Usage Context

    Asset Management

    CMMS

    External Context

    • Weather- Current, Forecast

    • Utility Rates

    • Demand Response Signals from Grid

    Work Request

    Energy Usage

    Data

    Advanced Analysis and Simulation

    Rich Data

    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


    Energy management application components

    Energy Management Application Components

    inTouch

    for real-time

    view of energy

    usage

    Intelligence-EMI for KPIs

    WIS for usage

    reports

    System Platform

    CEM

    IAS

    Historian

    WIS

    Work

    Flow

    Energy

    Database

    Offline

    Meters

    SmartGlance

    Mobile

    Reporting

    DAS- PLC

    DAS- Modbus

    DAS- BACnet

    Industrial

    Automation

    PLC

    DCS

    Building

    Management

    System

    Online

    Connected

    Meters

    • Meters for:

    • Electric Power

    • Compressed Air

    • Steam

    • Water

    • Gas

    • Chilled Medium

    BACnet

    LonWorks


    Cem meter objects

    CEM Meter Objects

    Energy Usage Transactions

    Energy Database

    CEM EngineService

    • Single Connection to Energy Database

    • One per Engine

    • Tested with 500 meters

    • Throttle DB access based on CPU

    Accept External Rate Schedule

    Meter Objects

    • Manage Device (meter)

    • Configure & Apply Rate Schedule

    • Read meter at intervals

    • Collect data values to add context to reading

    • Collect additional data from meter and send to Historian

    • Store and forward

    Historian

    Energy Data Points

    ArchestrA Infrastructure

    And I/O Drivers, Alarms

    Alarms

    Meter Related Alarms

    Makes Dumb Meters Smart!


    Cem event objects

    CEM Event Objects

    Energy Usage Events

    • Examples of Events

    • Production Order

    • High Flow

    • Equipment State

    • Shift

    Energy Database

    CEM EngineService

    • Single Connection to Energy Database

    • One per Engine

    • Tested with 500 meters

    • Throttle DB access based on CPU

    Event Objects

    • Triggers defined and monitored

    • Assign meters to relate to event

    • Trigger meters to read

    • Collect data values to add context to event (lot ID, process values, etc.)

    • Collect additional data from meter and send to Historian

    Historian

    Energy Data Points

    Event Related Alarms

    ArchestrA Infrastructure

    And I/O Drivers, Alarms

    PLC Registers, Database queries, MES objects, etc.

    Alarms

    Alarms

    Event Related Alarms


    Cem data validation editing

    CEM Data validation/editing

    • Offline mode

    • Data Editing

    • Interpolation of gaps


    Cem 1 5 release november 2012

    CEM 1.5 Release: November 2012

    • Performance for 30,000 meters

    • Wonderware Intelligence Model and content for CEM

    • Auto-interpolation of Offline data

    • Reports improvement

    • Billing Report


    Performance

    CEM 1.5

    Performance

    • Ensure performance for 30,000 meters for:

      • Configuration (Hierarchies)

      • Runtime (define architecture platforms/engines)

      • Visualization (Summary display)

      • Reporting (parameterizing and execution)

      • Editing (CEM Web App)

  • Provide a Deployment guide

  • Assumptions:

    • Single galaxy

    • 3 years of data @15 minutes recordings


  • Intelligence for cem

    CEM 1.5

    Intelligence for CEM

    • Self-Service access to CEM data. Enable end-users to:

      • Do their own analysis of CEM data

      • Build their own reports/dashboards on CEM data

  • Put CEM data in context with other sources (MES, Historian, alarms, etc.)

  • Quick time to value with pre-defined content


  • Cem reports

    CEM Reports


    Wonderenergy demonstration

    WonderEnergy Demonstration

    • A simulated Brewery

    • Consumes electricity, gas, and water to brew beer

    • Underlying simulation to “operate” the brewery

    • Shows real-time and historical information

    • Used to demonstrate concepts and features


    Cem use cases

    CEM Use Cases


    Use cases

    Use Cases

    • Food and Beverage Plant

    • Large Campus

    • Central monitoring of distributed sites


    Food and beverage plants

    Food and Beverage Plants

    • Single Plant- Stand-alone

    • Multiple Plants- 9 Plants on one system

    • Global Rollout- Dozens of plants


    Large campus

    Large Campus

    • Example1: Combined Building Automation and Energy Management

    • Example 2: Energy Management with Future for other applications


    Central monitoring of distributed sites

    Central Monitoring of Distributed Sites

    • Example 1: 2000+ Distributed Sites

    • Example 2: Central Reporting from global locations


    Energy management scenarios enabled by workflow

    Energy Management Scenarios Enabled by Workflow

    • Peak demand charge avoidance

      • Reduce load to avoid charge

  • Automated Demand Response in complex operations

    • Day ahead- opt in/out

    • Day of- execute, recover

  • Co-Gen Make vs. Buy

    • When wholesales prices for gas give better value than electricity

  • Energy usage based maintenance

    • Detect plugged filters, failing motors and equipment

    • Notify maintenance people and CMMS

  • Energy data collection system not working properly

    • Notify maintenance to investigate and fix

    • Notify Energy Manager that data gaps exist


  • Cem roadmap

    CEM Roadmap


    Cem 2 0 ideas

    CEM 2.0 - Ideas

    New ideas

    Demand Response

    Config. Produc-tivity

    Diag-nostics Tools

    Meter Manage-ment

    Voice of Customer Program


    Target monitoring

    CEM 2.0

    Target Monitoring

    • Target Definition: energy measure, reference period or event, meters, minimum & maximum, deviation,

    • One or more target by meter, event

    • Input of targets by: Input Source, File, Databaseobject (similar to rate)

    • Target tracking: inequality, CUSUM, trend, ArchestrA script

    • Target trackingenabled/disabledatruntime

    • Alerting: Alarm, email, IM, Workflow


    Validation estimation and editing vee

    CEM 2.0

    Validation, Estimation and Editing (VEE)

    • Option to auto distributeenergy usage across offline intervals

    • Edition of offline recordset, with auto linearinterpolation

    • Compute deltas and costsupon entry/edition of data

    • Auto load offline meter data from a folder (operate as RTU)

    • Audit log for edition of values

    • Estimation of values whilemeteris offline:

    • by linear extrapolation

    • Custom script


    Meters miscellaneous

    CEM 2.0

    Meters - Miscellaneous

    • Allowvirtual meters to have offline child meters

    • Allow for an Historian input source for meters

    • Meter Replacement

      • AdditionalMetaData: serial number, installed date, calibration, etc.

      • Counter value override

      • Allow for non-recording mode


    Diagnostics

    CEM 2.0

    Diagnostics

    • Compare Galaxy with CEM Database

    • Bettererror messages in ArchestrAlogger, with identification of source of problem.


    Database administration

    CEM 2.0

    Database Administration

    • Archive

    • Purge

    • Restore


    Configuration productivity

    CEM 2.0

    Configuration Productivity

    • Create strings automaticallywith default options whendefining configuration items

    • Do not requiremeta-data whendefining a folder

    • Pre-defined configuration items uponfresh installation (meter types, manufacturers, models, units, etc.)


    Demand response stretch goal

    CEM 2.0

    DemandResponse(stretch goal)

    • Demand monitoring object, withtarget (re-usemeterobject?)

    • ArchestrA Symbol in support of demandresponse


    For more information on cem

    For more information on CEM

    • Product Website: www.wonderware.com under Products

    • eLearning on training.wonderware.com

    • Business Development: [email protected]

    • Sales: [email protected]

    • Product Manager: [email protected]

    • Product Marketing Manager: [email protected]


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