Ohio Energy
Workshop K
Energy Savings in Manufacturing …
Understanding the Technology &
Business Cases for Intelligent Motor
Control, Variable Frequency Drives,
Energy Management, and Advanced
Process Control
Tuesday, February 18, 2014
1:45 p.m. to 3 p.m.
Biographical Information
Dave Mayewski, Business Development Leader, Cleveland Sales District
Rockwell Automation, 8440 Darrow Rd., Twinsburg, OH 44087
330-486-6634 Fax: 330-486-6634 [email protected]
Dave Mayewski is a Business Development Leader for Rockwell Automation in Twinsburg, Oh.
In this role he represents Rockwell Automation at technology events and in developing
partnerships in emerging markets and technologies. Previously at Rockwell Automation he
served as the Regional Commercial Manager for the Architecture and Software product
business and as a System Solution Manager working with customers and business units across
a broad range of industries to solve their control applications. Dave leads architecture
developments in industry verticals including power generation and advanced energy and in
engagements with key universities. Prior to Rockwell Automation he worked in roles of
increasing responsibility engineering systems for process and machinery applications. Dave is
a US Military veteran serving for 7 years in several deployed campaigns and holds bachelor’s
degrees in Electronics Technology, Marketing and Business.
Fred M. Discenzo, Ph.D., Manager, Diagnostics & Sensors
Rockwell Automation, 1 Allen-Bradley Dr., Mayfield Heights, OH 44124-6118
440-646-7325
[email protected]
Dr. Discenzo is the Manager of Rockwell Automation’s Advanced Technology Laboratory in
Cleveland Ohio and is a Rockwell Automation Fellow. For the over 30 years he has held
various research and technology management positions with major corporations. Dr. Discenzo
currently holds over 60 US patents and has published many papers spanning artificial
intelligence, machinery diagnostics, sensors, control, power scavenging and artificial neural
networks. His research efforts have earned him multiple corporate awards and trade industry
awards. He is frequently called on to assist customers in challenging programs involving new
technologies, sensors, analysis, diagnostics and controls. He has two bachelor’s degrees in
mathematics, a master’s degree in polymer physics, and a doctorate in systems and control
engineering. Fred represents Rockwell Automation on various university / industry advisory
committees, he serves on multiple conference committees and is the board chairman of the
Machinery Failure Prevention Technology (MFPT) Society.
About Rockwell Automation
Rockwell Automation (NYSE: ROK), is a leading global provider of automation, power,
control, and information solutions that help manufacturers achieve a competitive
advantage in their businesses. Headquartered in Milwaukee, Wis., U.S.A., the company
employs about 21,000 people serving customers in more than 80 countries.
Energy Efficiency and Intelligent Motor Control
Rev 5058-CO900B
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Rockwell Automation At A Glance
Fiscal 2012 Sales
 $6.26 Billion
 > 50% outside the U.S.
 22% in emerging markets
Two Segments – One Business
 Architecture & Software
 Control Products & Solutions
Leading global provider of industrial
power, control and information solutions
Global Reach
 22,000 employees
 PartnerNetwork™
 80+ countries
Serving Customers for 100+ Years
 Culture of integrity &
corporate responsibility
 Domain expertise
 Technology innovation
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
2
Global Leadership & Recognition
Innovation
Top 100
Innovative Companies
Ethics & Integrity
Top 100
Global Innovators
World’s Most Ethical
Companies
Better Business Bureau
International Torch Award
Corporate Responsibility & Sustainability
Top 100
Company Sustainable
Performance Leader
Company Index
Corporate Responsibility
Most Sustainable
Companies
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
3
Why Manage Industrial Energy?
Top Market Pressures
Total Energy Consumption
by Sector
Source: US Energy Information Agency:
Industrial sector consumes most energy !
Aberdeen Group Report 2011
Energy is one of the most difficult costs to manage in a production
environment but can result in significant savings
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Consider…
 Motors consume 65% of total industrial electricity
 On average 60% of fan systems are oversized
 Most chillers are oversized by 50–200%
 30% of energy used in a building is unnecessary or inefficient
 Compressed air systems’ average efficiency is 15%

Most energy efficiency improvements in industrial
facilities or manufacturing processes are due to how
energy is managed rather than new technologies
deployed.
Most energy improvement initiatives drive a 15%
reduction in use!
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Optimizing Plant Performance,
Protecting Your Investment
 Variable Speed Drives
• Electronic overload protection relays
 Soft starters
• Packaged & pre-engineered solutions
 Condition monitoring
• Turnkey motor control solutions
 Supporting capital investments long term
• Asset management
Control
|
Communicate
|
Protect
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
6
Intelligent Motor Control
The Advantage
Rockwell Automation defines Intelligent
Motor Control as a reference architecture
for the integration of motor control devices
to your plant-wide control system
EtherNet/IP
Intelligent Motor Control leverages your
investment in automation to provide
continuous optimization in:
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
7
If Machines could talk what would they
say?
 Production rate
 Status
 Hours of operation
 Good parts / bad parts
 OEE
 Energy Consumption
 Diagnostics MTTR
 Remote monitoring
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
8
Motor Control Options
Across the line starter
-Full Voltage Start
-Fixed Speed
Soft starter
- Reduced voltage
-Fixed Speed
Variable Frequency Drive
- Variable Speed
Choosing the best product based on the process and energy goals
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
9
Motor Control Centers
Motor Control Centers – equipment installed in single assembly
Maintainability, Safety, Simplified Installation
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
10
Smart Motor Controllers

Belts, gears and machinery can be
damaged by across-the-line starting
180%


Reduce inrush currents ( peak demand
charges) and excessive starting torque
A 50% reduction in voltage results in a
75% reduction in motor torque

Lengthens system life by reducing
mechanical stress during starting by
using Soft Start

Extra Savings – reduced labor and
maintenance costs
Full Voltage
Torque
100%
Reduced Voltage Torque
0
Percentage of Full Speed
100%
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Variable Speed Drives
Reduction of energy consumption through adoption of variable speed
control.
Reducing the speed of a
variable torque application
by 20% can save up to 50%
in energy consumption
Key factor in determining the replacement of control valves
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
12
Traditional Flow Control Methods
 When Fluid Capacity is fixed but the demand is variable Lowest 1st
Cost solutions were:
Control Valve- Restriction of Flow,
with a resulting INCREASE in
pressure. Pressure is increase until
desired flow rate is achieved
Bypass valve- A valve diverts
required flow to process, and
excess flow is re-circulated through
the pump again
ON-OFF control- pump motor is
started until setpoint is reached
then shut off
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Typical Flow Requirements
Key Element is Defining the Average Flow Requirement
Typical LOAD PROFILE in Process Flow Fan (or Pump)
12
11
10
9
% Time
Operating
in GPM
Range
8
7
6
5
4
3
2
1
0
10
20
30
40
50
60
70
80
90
100
% Design GPM Range
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Savings With Adjustable
Frequency Drives
Air Handler - System Profile vs Time
40%
TIME
%
40%
10%
40
10%
60
80
100%
FLOW (CFM)
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Savings With Adjustable
Frequency Drives
Operating Cost Comparison –
Outlet Damper to Variable Speed Drive 100HP
100
$31,540
Outlet Damper
Throttled Flow
60
HP
40
$15,031
Variable Speed
20
20
40
60
80
Variable Flow
100
% CFM
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Savings With Adjustable
Frequency Drives
Pumping System , Throttled Flow
Modulating Variable System Load Profile
with a Throttling Valve
Full Flow
Reduced Flow
Valve
To Process
Pump
Process
Feedback
Full HP Required
Control
MOTOR
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Savings With Adjustable
Frequency Drives
Pumping System , Direct Variable Flow
Modulating Variable System Load Profile
with an AC Drive
Reduced Flow
Valve
To Process
Pump
Process
Feedback
Reduced HP
Proportional to Flow
Control
MOTOR
Direct Variable Speed
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Savings With Adjustable
Frequency Drives
Operating Cost Comparison –
Throttling Valve to Variable Speed Drive 100HP
100
90
$32,637
Throttling
80
Total
Head
in
Feet
70
60
50
40
$16,053
Variable Speed
30
20
10
0
200
400
600
800
1000
1200
1400
1600
1800
2000
U.S. Gallons per Minute
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
ROI Ex - VFD for Electronic Throttling
25 HP Induction Motor
100% Speed
100% Load
25 HP
0.08 $/kWh
12 H/Day
360 D/Year
$6785 per year!
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
ROI Ex - VFD for Electronic Throttling
25 HP Induction Motor with VFD
Incentive:
25HP x $60/HP = $1500
25 HP
60% Speed
22% HP
0.08 $/kWh
12 H/Day
360 D/Year
$1493 per year!
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Drive Purchase Example ROI
ROI Ex - VFD for Electronic Throttling
Simple Payback:
Drive Cost / Annual Savings
($3350 - $1500 Incentive) / ($6785 - $1493)
1850 / 5292 = 0.35 years
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
On the web
Rev 5058-CO900B
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Realize the potential savings by installing a VFD !
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Efficiency Improvements
Typical Project Savings
Capital Cost
Annual Savings
Payback Period
(yrs)
Compressed Air
$142,000
$128,000
1.1
Process (oven, cooker, etc) Optimization
$330,000
$230,000
1.4
Tank Venting
$20,000
$15,000
1.3
Ammonia Compressors
$42,500
$28,500
1.5
Mixer VFD's
$30,000
$22,000
1.4
Boiler Optimization
$37,500
$46,000
0.8
Production Energy Save Mode
$145,000
$105,000
1.4
HVAC Optimization
$200,000
$100,000
2.0
Demand Management
$400,000
$200,000
2.0
$1,367,000
$914,500
1.5
Projects
Totals:
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Management > Challenges
The traditional outside-in approach views energy as:
 An unavoidable cost of doing business
 Measured by overall facility usage
 Managed only by using less
 Lack of information to begin managing energy
 Challenge for energy usage data to be aggregated & tracked
 Improvements are often seen as expenses instead of investments
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Effective Energy Management
You Can’t Manage
What You Don’t Measure
Turbine
Refrigerator
Mixer
Chiller
Boiler
1. Know what you are using, (who’s using it),
and what that usage is over time.
2. Understand why you are using it.
3. Understand how energy consumption is
contributing to your costs (e.g. peak demand).
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
How are you Managing your Energy Usage?
Plant Management
How do we
avoid costly energy
demand charges?
What are the
energy intensive
Scheduling
processes?
How much energy
is consumed to make
this product?
How do I create
a more energy
efficient machine?
Knowledge Worker
How to ensure
uptime and reduce
energy cost?
Machine Builder
How do I increase
throughput while
reducing Quality
energy usage?
Information Technology
Control Engineering
Operator
Planning and Logistics
Maintenance
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Energy Monitoring and Reporting
Energy information to make intelligent decisions
Demand vs.
consumption charts
Excel Reports
48hr dashboard
Demand charts
Trend
Tabular reports
Dashboard
Power Quality
reporting and analyses
Customized examples
Real time access to
Power Meters
Demand and
consumption reporting
Advanced billing
capabilities
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
29
Overcome the Challenge
 Gain accurate visibility of energy consumption of your assets
 Compare energy efficiency across plants and assets with normalized data
 Analyze energy usage trends compared to historical patterns and
forecasts
 Trigger alerts from unexpected deviations
 Prioritize actions and investments based on financial and operational
parameters
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Industrial GreenPrintTM Load Profiling –
Monitor / Analyze
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Industrial GreenPrintTM Load Profiling –
Monitor / Analyze
 One 125HP, Three 40HP Fans
 Incentives:

125HP x $60/HP = $7,500

(3)40HP x $60/HP = $7,200

Total Incentive = $14,700
 Approximate Cost of VFDs:

125HP: $13,500

(3)40HP: $19,500

Total Cost: $33,000 - $14,700 = $18,300
 Annual Savings: $67,000
 Simple Payback = Drive Cost / Annual Savings

$18,300 / $67,000

Payback = 0.27 Years
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
General Control Block Diagram
Model Predictive Controller
Optimizer
Trial
outcomes
Trial
actions
Control
actions
Process
Model
Process
Measurements
Disturbances
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
33
Benefits of a Model-Based Approach
PID
LogixMPC
 Simplified controller design & maintenance (especially in large MIMO
applications)
 Explicit handling of process constraints
 Improved machine stability (e.g. lower process variability)
 Enhanced efficiency (e.g. by running closer to constraints)
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
34
Example 1 – Moving Beyond Setpoint
Control
Without MPC
• Larger temperature variations
• Less stable production rate
• Higher energy use for re-work
• No control over fuel usage
Higher
Variation
Lower
Production
With MPC
• Smaller temperature variations
• More stable production rate
• Less energy use for re-work
• Direct control of fuel usage
Lower
Variation
Higher
Production
Production Rate
Slab Temperature
Without MPC
With MPC
MPC
PID
PID
PID
PID
PID
PID
Furnace
Slab
Production
(Extruders)
Confidential – For Internal Use Only
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
35
Why Customers Choose Rockwell Automation
to Help Them Manage Energy
Rockwell Automation is unique:
 We have extensive knowledge in the industrial
environment

Leverage your existing automation and control systems

Can combine Energy Consulting, Products, and Turnkey
Systems capabilities with one partner

RA’s project management methods and quality assurance
help you mitigate risk and ensure your satisfaction
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
Questions?
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
37
For more information:
http://ab.rockwellautomation.com/drives
http://discover.rockwellautomation.com/energy
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
38
Thank You!
Follow ROKAutomation on Facebook & Twitter.
Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900B
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.