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1© 2006 OSIsoft, Inc. – Company Confidential
Energy ManagementEnergy ManagementThe Infrastructure ApproachThe Infrastructure Approach
Dr. J. Patrick Kennedy, CEO and President
2© 2007 OSIsoft, Inc.
The Problem – Utility SideThe Problem – Utility Side
3© 2007 OSIsoft, Inc.
The Problem – User SideThe Problem – User Side
Cost of Energy Going up– Not only actual, but built in (e.g.
Recycle Pulp) Reliability Decreasing Unused Flexibility New Tariffs
4© 2007 OSIsoft, Inc.
Responses on the Horizon…Responses on the Horizon…
Dynamic changes occurring in the market
– Deregulation
– Cap and Trade Certificates
– Market Based Pricing Demand Response Time of Day LMP
5© 2006 OSIsoft, Inc. – Company Confidential
Case Study - KodakCase Study - Kodak
6© 2007 OSIsoft, Inc.
The Largest of Eastman Kodak’s Worldwide Manufacturing Sites
Located in Rochester, New York Referred to as a “City Within a City” 1300 Acres (5,200,000 sq m) 150 Buildings Nearly 30 Miles of Roads
Kodak ParkKodak Park
7© 2007 OSIsoft, Inc.
Facts and FiguresFacts and Figures >20,000,000 Square Feet (2,000,000 sq m) 11,000 Employees Operates Its Own Fire Department Operates Its Own Railroad Operates Its Own Water and Waste Water
Treatment Plants Operates Two Power Plants
8© 2007 OSIsoft, Inc.
Kodak Park Kodak Park
9© 2007 OSIsoft, Inc.
Kodak Park UtilitiesKodak Park Utilities
Kodak Park Utilities Power Plants– 2,000,000 Pound/Hour Steam Load– 125 MW Electric Load– 80,000 Ton Refrigeration Capacity– 30,000,000 Gallons/Day Process Water Load– 35,000 SCFM Compressed Air Load
10© 2007 OSIsoft, Inc.
Utility MeteringUtility Metering
600 Electric Distribution Meters 600 Additional Distribution Meters for:
Steam, Chilled Water, Brine, Compressed Air, Process Water, Nitrogen, Natural Gas, etc.
Significant Metering Used within the Power Houses to Manage the Generation Side
11© 2007 OSIsoft, Inc.
InterfacesInterfaces
BAS– Rosemount - Fix
32– Siemens - Apogee– Emerson - Delta V– SQL Based
Historians
DCS– Fisher Provox– Westinghouse
WDPF– Westinghouse
Ovation– Taylor Mod 300– Emerson - Delta V
12© 2007 OSIsoft, Inc.
Nodal Power MarketsNodal Power Markets
13© 2007 OSIsoft, Inc.
GoalsGoals
Reduce utility costs at Kodak Park through improved demand side management
Consolidation of the utilities data Create Awareness via the Web Grow a Culture of Energy
Efficiency
14© 2007 OSIsoft, Inc.
Solution – Current status Solution – Current status
Over 100,000 PI Points currently established
23 ProcessBook / DataLink Users 150 Concurrent Web Users 180 + iView Pages 27 Interfaces installed
15© 2007 OSIsoft, Inc.
16© 2007 OSIsoft, Inc.
17© 2007 OSIsoft, Inc.
18© 2007 OSIsoft, Inc.
Numerous water main breaks due to pressure control issues
Increased visibility and easy access to this data has improved control and reduced the frequency of these “costly” water main breaks dramatically.
19© 2007 OSIsoft, Inc.
Expanded use of our Energy Information System has been an effective tool to help enable us to consolidate two High Purity Water Systems and a de-mineralized water system down to just one High Purity Water System.
20© 2007 OSIsoft, Inc.
21© 2007 OSIsoft, Inc.
22© 2007 OSIsoft, Inc.
23© 2007 OSIsoft, Inc.
24© 2007 OSIsoft, Inc.
25© 2007 OSIsoft, Inc.
26© 2007 OSIsoft, Inc.
Mini ProjectsMini Projects
Demand Side– Better correlation of MFG energy
usage to production volumes– Identified opportunities in
manufacturing to implement an energy conservation mode between product runs
– Extended carbon recovery cycles
27© 2007 OSIsoft, Inc.
Mini Projects IIMini Projects II
– More effective utilization of labs with fume hoods
– More effective “Time of Day” scheduling for lighting and HVAC
– Temperature / HVAC fan set points– System is considered an essential tool
during our energy savings workshops (Kaizens)
– Heightened awareness of many end users
28© 2007 OSIsoft, Inc.
Mini Projects Mini Projects Generation side findings
– Plant loading optimization– Boiler fan optimization– Exhaust head improvements– Better management of self generation vs.
purchased power– Improved deaerator utilization
29© 2007 OSIsoft, Inc.
Harvest TimeHarvest Time
The Energy Information System (EIS) has been an essential tool to help us reach our goal of:
““One Powerhouse for Kodak Park”One Powerhouse for Kodak Park” Collectively these efforts have
yielded savings into the millions of dollars.
30© 2007 OSIsoft, Inc.
Case Study – CodelcoCase Study – Codelco
Five Operating Divisions (Chuquicamata, Radomiro Tomic, El Salvador, Andina, El Teniente),
Each full mining/metallurgical complex (mining, concentrators, smelting, refining, leaching, solvent extraction, electrowinning, utilities, and maintenance)
31© 2007 OSIsoft, Inc.
Radomiro Tomic Architecture Radomiro Tomic Architecture
MODBUS PLUS
PI API NODEMODBUS PLUSNT WORKSTATIONSA-85
RED SUP. Y CONTROLRSC
RED DIVISIONALRD
GATEWAY
USUARIOS RSC
USUARIOS RD
PI SERVERPI-ORACLENT SERVER
SERV. ORACLEPRODUCCIONSCO UNIX
SERV. APLICACIONESWEB SERVERNT SERVER
100 MB
GATEWAY
100 MB
100 MB
100 MB
PI API NODECOLD BACK-UP
ARQUITECTURA FISICA
32© 2007 OSIsoft, Inc.
Teniente Mine/ConcentratorTeniente Mine/Concentrator
EL TENIENTE
SERVIDOR PI
OTROS SERVIDORES
SERVIDOR
CONTROL CALIDAD
PI-API
SERVIDOR
DE BDR
(futuro)
CLIENTES PI DIVISIONALES
APLICACIONES
ESPECIFICAS
ARQUITECTURA DE SISTEMA PI EN MINCO (ACTUAL)
SOFTWARE
HARDWARE
TRAT.RELAV.
MODICON MODBUS+
NT
SWITCH
BRIDGE
CH1 - CH2/3 - SAG - MOL - FLOT - MOLIB
HONEYWELL TDC-3000 LCN
VMSPI-NET
FILTROS
PI-APINT
A LLEN-BRADLEY DH+
NT
20,000 TAGS
INGRESOMANUAL
FFCC TTE-8CHANCADO TTE-6
GE 90/30 DH
ESTACOPERAC
ESTACREMOTA
TTE-6
PI-API
PI-CLIENTE
33© 2007 OSIsoft, Inc.
ProjectsProjects
Water Management Environmental Regulation Asset Management Troubleshooting Operating Effectiveness Energy Management Inlet Vanes Utilities (Power, Steam, Air) Trading/Power Purchase
34© 2007 OSIsoft, Inc.
Lessons LearnedLessons Learned
No BIG BANG – 1000 little bangs Continuous Improvement Process Combined Capital and Intelligence
Operation Infrastructure Approach – Remove
Infrastructure from Projects Lowers the Cost of Curiosity
