PQ04 Understanding Power Monitoring
Understanding Power Monitoring Randy Keranen Drives, Motors, and Power Monitors Product Manager April 9, 2015
Related Classes at the Expo PQ05 Energy Intelligence: EnergyMetrix PQ06 Energy Intelligence: VantagePoint Energy PQ02 Power Quality and Monitoring.. PQ03 Using Test Equipment to Detect and Measure PQ Issues PD02 Power Quality and Monitoring
Agenda Main Objectives Why do we care about Energy? Electricity Basics PT, PF, PQ, Consumption & Demand The Electricity Bill 2 Examples Power Monitors Power Monitor Software PowerMonitor 5000 Setup Demo
Sustainable Production Inputs Add this flow to next slide Materials / parts Information Materials / parts Energy Materials Information Energy is a great place to start
Online Article from 6/7/15 New Minneapolis ordinance aims to reduce energy, Save money We want people to understand where their energy comes from, how they re using it, and how efficient buildings are in the city. - These commercial buildings account for more than 40% of the energy used in the city. http://kstp.com/news/stories/s3465838.shtml?cat=1
Why Manage Industrial Energy? The Industrial sector consumes more energy than any other. Total Energy Consumption by Sector Top Market Pressures Source: US Energy Information Agency: Aberdeen Group Report 2011 Rockwell Automation is an Industry Leader in helping customers optimize their production operations to reduce cost
What is the difference? For the sake of this discussion: Power/Energy Management: Providing solutions that enable a customer to optimize the consumption and demand of energy in their plant or at a specific process. Power Quality Management: Providing solutions that minimize the impact of both external and internal power quality events/conditions that can impact the up-time or performance of a plant or a specific process. Both solutions have similar aspects or parts: Power Monitoring, Data organization or analysis through a tool or software, *System optimization *Very different remediation solutions (Solving a different problem)
The Power Triangle Real Power (kw) produces heat, mechanical and chemical work V&I are in phase Reactive Power (kvar) is stored in magnetic and electric fields. V&I are 90 O out of phase Real Power (kw) Reactive Power (kvar) Apparent Power (kva) dictates the capacity requirements of the system
Power Factor Ratio of Real to Apparent Power PF = Real Power (P) Apparent Power (S) Power factor can be Leading or Lagging Lagging - the load is more inductive (i.e. motors) Leading - the load is more capacitive Utilities may impose a Power Factor Penalty
Power quality Bad power quality Sag, transients Ongoing harmonic distortion Good power quality Nice, clean, balanced voltage sine waves Some current THD, not enough to impact the voltage
Power Quality Voltage Sag/Swell Harmonics Transient Detection
Power Management (Direct cost) Consumption Real, Reactive, and Apparent Energy Demand Real, Reactive, and Apparent Power Time interval determined by utility Time of day matters Ratchet Penalties Power Factor Lagging (penalty for reactive energy draw) Leading (giving away energy to utility)
Energy Power = Rate of Energy Transfer Energy like an odometer Energy = Power * Time Interval (Integrated) Units of measure: Watt-hours (Wh) kwh, MWh A little weird since time is part of the energy unit Power like the speedometer
Demand Demand = energy usage averaged over an interval Momentary peaks do no damage Sustained overloads cause heating and damage Demand profiles Plant B uses more energy but the same demand as A They both need the same supply capacity Demand charges compensate the utility for investment 1300 kw 1300 kw Plant A low load factor Plant B high load factor
Xcel Energy Demand Charge Xcel Energy Demand Charge Definition: Charge to commercial and industrial customers for the fixed costs of the electric capacity required to meet the peak electric loads on Xcel Energy s System. Applies to the highest 15 minute kw demand during the billing period Ratcheting Demand
Demand Charges are 46% of the billed amount Price Impact
Another Electric Bill Example
Demand Ratcheting
Your Utility Bill Expained The Utility Bill video -- > http://www.youtube.com/watch?v=yo2jojb VJHo Understand your Xcel Energy Bill -- >https://myaccount.xcelenergy.com/ebill/und erstandingbill_mn.jsp
Energy Usage vs. Production Energy usage is traditionally metered at one point on the outside of the building Limitations: Difficult to correlate energy consumption with real-time production information Difficult to compare energy used during different batches or production run What is happening within the factory with the energy resources being used is typically a black box What am I actually making with all of these resources? How much electricity was used during this production run? How is the power quality? How much energy is consumed during peak? Measured to the Building
Energy Usage vs. Production EtherNet/IP ACT LNK RS-485 RS-485 STATUS Powermonitor 1000 RX TX Mod Net + - SHLD EtherNet/IP RS-485 RS-485 STATUS EtherNet/IP Powermonitor 1000 RS-485 RS-485 STATUS Powermonitor 1000 RX TX Mod Net RX TX Mod Net ACT LNK + - SHLD ACT LNK + - SHLD Allen-Bradley Powermonitor 3000 L1 EtherNet/IP ACT LNK RS-485 RS-485 STATUS Powermonitor 1000 RX TX Mod Net + - SHLD Identify large or critical loads Install PowerMonitors where needed Implement monitoring software Drive accountability Utility Feeds 138 kv East West Monitor results FactoryTalk EnergyMetrix Utility meter kwh Powermonitor 3000 M6 25.04M WATT Switchgear 12,470 V Powermonitor 1000 Typical for 5 Boiler house Substation 4160 V Power house Substation Production Substation #2 Production Substation #1 480 V MCC 4 480 V 480 V Measured to the Production Line MCC 5 MCC 3
Product Overview How it Works The PowerMonitor is wired to PTs (Potential Transformers if required) and CTs (Current Transformers) The PowerMonitor will then measure current/voltage and calculate energy related data This data can be read on the local LCD, be read into an AB PLC, be viewed through RSPower or RSView, or logged to FactoryTalk EnergyMetrix Calculate energy related data Measure Current/Voltage CT PT
How to Differentiate Power Monitors Measurement Capacity Consumption / Demand Power Factor Power Quality: Sag/Swell Detection, Harmonics, Transients Waveform Capture Accuracy Accuracy as a percentage; Revenue Grade Accuracy Networking / Communication EtherNet/IP, ControlNet, DeviceNet, Wireless, Serial Local Display? Internal Data Logging Capacity Record activity without external data logging software
How to Differentiate Power Monitors Embedded Inputs / Outputs Status Inputs: Log data from external meters via pulse inputs Relay Outputs: Direct control over connected devices KYZ Outputs: Standardized pulse output for electrical metering Setpoint Control Activate outputs based on internal metering setpoints Example: Turn off Relay 1 if power consumption exceeds 3 kwh CIP Energy Support CIP Energy: Common Industrial Protocol for Energy Data
PowerMonitor W250 Metering Consumption (kwh) Demand (kw) Derived in EnergyMetrix Communication Wireless to Serial Receiver 802.15.4 Wireless standard Modbus RTU from receiver Key Features Wireless repeater for extended range Integrated current transformer coils Wireless diagnostic tools in EnergyMetrix Self-configuring wireless networking Future Developments Ethernet receiver Wireless Pulse Meter Wireless Sub-Meter
PowerMonitor 1000 Metering Consumption (kwh) Demand (kw)* Power Factor (%)* Communication EtherNet/IP Serial * Optional Key Features Embedded web page for real-time data and configuration DIN-rail mounted Diagnostic utility for incorrect wiring Two status inputs for external metering (Water, Air, Gas, etc.) Integrated display for configuration Sub-Process Meter
PowerMonitor 500 Metering Consumption (kwh) Demand (kw) Power Factor (%) Communication EtherNet/IP Serial Key Features Door mounted Large backlit display for real-time monitoring Fully configurable by touchkeys and display Configurable alarming Integration with FactoryTalk EnergyMetrix Integrated analog or digital outputs (optional) At-Process Meter
Other Energy Monitors Symcom egauge http://www.symcom.com Model 777-777-KW/HP-P2 - Our unit has a DeviceNet Card back to the PLC http://www.egauge.net/ EG 3000 BACnet/IP to Ethenet/IP via a Prosoft Gateway Warehouse fans and Compressor - 4-20ma from CT s to the PLC
PowerPad or Fluke Metering Consumption (kwh) Demand (kw) Power Factor (%) THD, Crest Factor Sag/Swell Harmonics (n=50) Waveform Capture Communication Serial USB Key Features Display screen for data analysis Memory for up to a month of data collection Separate probes integrate with meter for flexible configuration Waveform capture and review without a separate software required Automatic current probe recognition and scaling Sub-Process Meter
PowerMonitor 5000 Metering Consumption (kwh) Demand (kw) Power Factor (%) THD, Crest Factor Sag/Swell, Flicker Harmonics (n=127) Waveform Capture Communication EtherNet/IP EtherNet/IP DLR* ControlNet DeviceNet * Future Releases Key Features Logix Add-On Profile (v22) Virtual correction of wiring errors Revenue Grade Accuracy (Class 0.2) IEEE 1588 Time Synchronization CIP Energy Support Status Inputs / Relay Outputs ControlFLASH Upgradable Flicker Sub-cycle Transient Detection Feed Meter
PowerMonitor 5000 - Demo Live demonstration of the PowerMonitor 5000 PowerMonitor 5000 USB Driver Installation and Configuration http://literature.rockwellautomation.com/idc/groups/literature/d ocuments/in/1426-in001_-en-p.pdf Metering Consumption (kwh) Demand (kw) Power Factor (%) THD, Crest Factor Sag/Swell, Flicker Harmonics (n=127) Waveform Capture Feed Meter
Understanding Energy Reduce Consumption Power-down equipment when not in use Install more energy-efficient equipment Repair/Replace broken equipment Reduce Demand Stagger startups Perform startups during off-peak hours Reduce frequency of startups Correct Power Factor Install capacitor banks to balance load Reduce operation of inductive loads Reduce Downtime Optimize preventative maintenance Diagnose power quality issues impacting equipment health and grid stability
Plant level - CAPEX project estimating Simple ROI 1. Do Nothing Assume similar operation, Rate Increases on kwd, kwh. 2. Improve PF Improve from 0.830 to 0.900 FY13 $1,272,272 FY14 $1,296,361 -$24,088 FY13 $1,272,272 FY14 $1,293,858 -$21,585 3. Demand Mangement Program Attack the max kwd rates and decrease by 10% FY13 FY14 $1,272,272 $1,232,261 +40,011 $64,099 Benefit when compared to Do Nothing 4. Demand Response Program Utility offers 24 hour look-ahead plan ~-$15,000 with a 50% reduction requirement, TBD by plant management FY13 $1,272,272 FY14 UNK +UNK
Questions to qualify Power Management Opportunities Who to talk to: Top Management Corporate Energy Manager Plant Manager Plant Energy Champion - CEM (Certified Energy Manager ) Sustainability Manager Energy Teams Questions to ask: End User Do you have a Corporate energy initiative? What is your monthly electric bill? What is your total energy cost as a percentage of your operating costs? Do you conduct any energy monitoring inside your plant? OEM Are your customers concerned with energy consumption? Do they include energy expectations in their specifications?
Energy Management Application Cycle Analyze Negotiating Better Utility Rates Managing Production Schedules Determining Actual Manufacturing Costs Driving Simple Behavioral Changes Optimize Understanding What-When-Where Energy is Consumed Monitor Efficient Energy Usage Improving Equipment Performance Handling Power Outages What is the next step? 36 Reduce Energy Cost, Waste, Emissions and Downtime
Related Classes at the Expo PQ05 Energy Intelligence: EnergyMetrix PQ06 Energy Intelligence: VantagePoint Energy PQ02 Power Quality and Monitoring.. PQ03 Using Test Equipment to Detect and Measure PQ Issues PD02 Power Quality and Monitoring You can find this items in the Solution Area SA1
Understanding Power Monitoring You can t control what you don t measure. Randy Keranen Thank You! Drives, Motors, and PowerMonitor Product Manager rkeranen@wernerelec.com