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.
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