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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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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

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
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
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
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
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 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.
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
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