Industrial Energy Efficiency as a System? Energy Management as a significant part of the Solution. Prinya Paulprekskul November 2015

Transcription

1 Industrial Energy Efficiency as a System? Energy Management as a significant part of the Solution Prinya Paulprekskul November 2015

2 Ads of the future? Produced using 100% renewable energy! 25% fewer CO2 emissions than leading brand. Certified Green by ISO compliance. No carbon-based fuels were used in the production of this snack food. 2

3 Sustainability & Supply Chain Pressure 3

4 The Big Dilemma The facts The need Energy demand by 2050 Electricity by 2030 Source: IEA 2007 vs CO 2 emissions to avoid dramatic climate changes by 2050 vs level Energy management is the key to address the dilemma 4

5 Introduction... And Conculsion 5

6 Introduction... And Conculsion It is natural for Bulbs Traditional generation New generation What has changed.. Consumption 5 Life duration x5 6

7 Energy Efficiency as a source of energy Fuel Consumer 100 units 35 units 33 units 3 units saved at the energy source 1 unit saved at consumer plug 7

8 Who uses the most energy? 31% Our solutions make your Energy more Productive. 8

9 Easily identifiable Energy Efficiency Opportunities Industrial companies don t have sufficient information to know where to look for beyond the easily identifiable Energy Efficiency Opportunities Less obvious, higher impact: Energy Efficiency through Process and Machine Efficiency to reduce the energy consumed per unit of output! 9

10 Enlarged vision through Energy in Context Energy Information Energy Efficiency 15L per 100 km Energy Efficiency 15L per 100 km Energy Information with context Energy Efficiency 15L per 100 km Energy Efficiency 15L per 100 km profile of track Height Travel direction Travel direction Distance Distance 10

11 Energy in Context Real case Daily crashed stone Crusher #1 Energy consumed in production context Search for root causes and benchmark for best-practices implementation 450 Tn/8hs Morning Shift 540kwh Morning Shift Crew #A New staff Respect standard procedures for stone loading cycle 450 Tn/8hs Afternoon Shift 470kwh Afternoon Shift Crew #B Experienced staff Fine tuned the stone loading cycle 11

12 Real-time Active Energy Management Example NO FEED? SHUT DOWN! 12

13 When energy monitoring is combined with automation and control infrastructures, energy efficiency can grow by as much as 30%. 13

14 Optimize Process & production energy Process Automation System Part of the EcoStruxure integrated architecture for both Process management Energy management We make your Energy Productive Integrated process & energy architecture 14

15 \ : delivers process control for active energy management. Remove energy waste from your process in real time at the source of overconsumption. We make your Energy more Productive. 15

16 Identify Your Savings Opportunities If you change your operations, how much waste can you avoid? Plant Consumption kwh/ton.raw Mill (0~8) Evening (8~16) Morning (16~24) Night Benchmarking 16

17 Identify Your Savings Opportunities How much can you save? Daily Power Consumption 60,000 50,000 40,000 kwh 30,000 20,000 10, Target Actual 17

18 Step 2: Fix the Basics with Energy Aware Infrastructures Connect automation and control with energy monitoring systems to create an intelligent, energy aware infrastructure, giving insight into process energy. Integrated hardware infrastructure SEPAM ION 7650 EGX300 Gateway PM 6200 PLC VSD 18

19 Creating Energy Aware Infrastructures Power meter PM820 with module PM8ECC Connecting automation & control to power management enabling production energy optimization. TVDA Compact NSX100F main switch 2. Phaseo power supply ABL8 3. CANopen breaker 4. Modicon LMC058 Motion controller 6. Lexium SD328 stepper drive 7. Preventa Safety module XPS 8. Multi 9 circuit breaker 9. Altivar variable speed drive 10. Altivar variable speed drive 11. Magelis XBTGT HMI 12. Harmony tower light XVBC 14. Harmony E-stop enclosure XALK 15. Lexium servo motor BSH 16. Lexium stepper motor BRS 18. Lexium integrated drive ILE 19. Lexium integrated drive ILA 20. Absolute encoder XCC 19

20 Use global speech : your actuators are often oversized For pumps or fans : Real needs after calculation : 100 Over sizing for safety measures : 120 Choice in the catalogue : 130 Installed base : 1,3 x real need Mechanical devices are used for flow restriction The motor is operated with a bad efficiency rate! 20 20

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22 This is nothing new Mentioned in an article in Pump Engineer 2007 Mentioned in a article in the Motor Challenge Program already 1998 where they recommend to change the valves. 22

23 Power overview 0,75 5, IP21, IP kw ATV630 Wall mounting products IP21/UL Type1 ATV630 Floor standing ATV640 LH-products IP21/UL Type1 ATV660 Drive Systems IP23 ATV660 (690V ) ATV680 Low Harmonic Drive Systems IP23 ATV680 (690V) 23

24 Range for Harsh Environment ATV x x x 1250 with or w/o switch! Up to 22kW Up to 45kW Up to 90kW 24

25 Altivar Process Quick on features 10 year lifetime Normal Duty Pn (Overload 110%) High Duty Pn-1 (Overload 150%) Induction & Permanent Magnet Motor Operating temperature: -15 C to +50 C w/o derating Up to +70 C with derating on power Altitude: up to 4800m within defined conditions Harsh environment: Chemical env 3C3 - H2S, Ozone, SO2 - Salt mist Mechnical 3S3 - Pollution degree 3 - Coated boards IEC compliance: Enlarged THDi 48% from 100% to 80% of motor nominal load Conducted Emission IEC/EN Up to 45kW 400v C2 50m C3 150m Above 45kW C3 150m Human Machine Interface: Several languages more than 20 Customizable (units, ) Energy/Pump monitoring Trend and drift energy Dedicated application functions Removable HMI with RTC, fast replacement functions, innovative door mounting kit (hole Dia22), red backlight in case of error detection 2 slot for SHI options : Fieldbus Digital & Analog I/O Relays (3) Embedded Fieldbus: Ethernet Modbus TCP Modbus Options Fieldbus: Ethernet IP/Modbus TCP (dual port) DeviceNet CANopen Profibus & ProfiNet 25

26 Harmonic mitigation Standard At 80% load Other drives Altivar Process THDi = 52% THDi = 48% Perfect Harmonic mitigation embedded THDi = full load THDi = 80% load no Power Factor penalty Line current < motor current Less transformer losses Cos Phi # 1 Power factor < 0,9 Cos Phi # 1 Power factor > 0,9 Conditions : 230V/50Hz for 220/240V range 400V/50Hz for 400/480V range RSCE>120 80% motor load corresponds to usual sizing (pump design point) Power quality to avoid penalties 26

27 Cost optimized power options Savings Conducted Emission IEC/EN Up to 45kW 400v C2 50m C3 150m Above 45kW C3 150m Wall mounting Cabinet mounting L 27

28 Drive HMIs DTM - So Move Integration in SE solution Engineer tool for design and high level maintenance Full access to drive data Drive HMI Embedded industrial tool (Front cabinet) Dynamic QR code displayer Drive local mass storage Altivar Process Webserver 100% standard (0 software 0 versioning) Online HMI, focus on operation and maintenance Mobility 28

29 Webserver 1/2 Simplicity - Your Daily working tool & your favourite Browser - Embedded help - Multilanguage One click connection - Standard Ethernet Cable and Plug and Play Schneider-electric Wi-Fi dongle - Automatic recognition of the device (no IP address management) Network security - Hardening password policy - User profile (read only mode) - Web services can be disabled 29

30 Webserver 2/2 Business optimisation enabler : Energy and Process Dashboards Flexibility : Configurable home page; IU customization; User profile management 30

31 Direct access with Dynamic QR code QR code 2 doc: - Contextual link to advanced technical documentation for Troubleshooting Functions setting - Standard QR code reader - Take full advantages of the high resolution and color screens of a smart phone QR code 2 case : Direct link to Customer Care Centre - Automatic creation of technical support request - Pre-fill serial number and reference of the drive - Direct contact to the local support 31

32 Pump monitoring Pump curves embedded => Process optimization; operate close to the BEP Easy to set (5 points curve) for graphical monitoring of the operating point vs Best Efficiency Point Pump dashboards => Process management Key pump values, Efficiency, process KPI, cumulated volumes 32

33 Make the most of your energy 33