CT237 Real-Time Energy Monitoring and Targeting Best ... · PDF file• Net Promoter Score ... Capable of handling specialized product requirements and servicing niche markets and

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

CT237 – Real-Time Energy Monitoring and

Targeting Best Practices for Industrial Facilities

Presented by: JMP Engineering Inc.Mike Kipina, Director Business Development – Information Systems

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

Agenda

2

The JMP Difference

Energy Opportunity

Conestoga Project Profile (Food and Beverage Mfr.)

Distillery Project Profile (Food and Beverage Mfr.)

Toyota Project Profile (Automotive Mfr.)

Operational Excellence

Customers We’ve Helped

Next Steps


Our Purpose Guides Us

3

We help people and businesses realize their full potential by

continually redefining what is possible.

“Reducing facility energy costs with enhanced

visualization.”


GuaranteedPerformance

• If we commit to a solution, we will find a solution.

• We will gather all stakeholder’s definitions of project success, and work within our scope to meet those criteria.

• A risk identification and management document will be created and maintained.

• Factory and/or site acceptance tests will be delivered in advance, witnessed, and completed.

• Our fault indications and recovery methods will be industry leading.

• Customer closeout meetings will yield no outstanding issues.

ExceptionalCommunication

• We will acknowledge receipt of requests by the next business day (voicemails, emails).

• We will listen empathically, seeking first to understand.

• We will conduct a formal handoff of customer relationship details as part of our internal project kickoff.

• We will raise risks as soon as they are known, and always will include a mitigation strategy for review.

• We will proactively communicate such that the customer is never asking us for updates.

• We will involve all stakeholders in communication of relevant items.

• We will follow-up on system performance after project closeout as a longer term touch point.

Radical Commitment

• Every customer will feel like our most important customer because of our sense of urgency and responsiveness.

• We will promote teamwork and collaboration, operating in a unified, non-transactional manner with our customers.

• We will take ownership and show accountability.

• We will never leave a customer stranded, abandoned, or turn our back on a problem.

• We will provide 24 hour support to our customers, 365 days a year.

• We will ask ourselves each day if there is something we can do to make that day an exceptional one for our customer.

1 2 3

Our PromiseDrives Us


Our Culture Challenges Us

A culture of assume nothing.Thinking inside-out. A product of outthink, outdo. An engineeringcompany who constantly evolvesthe engineering of our own processesto deliver the best for our clients.Tireless at finding answers andcreating solutions. Our finest workoften comes after someone else hassaid it can’t be done. A guarantee ofperformance. People producingresults for you.


Our ValuesAlign Us

RELATIONSHIPS

LEADERSHIP

COLLABORATION

INTEGRITY

EXCELLENCE

RESPECT


Our Big Hairy Audacious GoalInspires Us

By 2035, we will be one of the world’s top 3 independent

system integrators in the provision of robotic, control, and

information solutions to industry.*

*According to the CSIA


Core CompetenciesContinually Redefine What is Possible

SayDo Ratio: What we say, we do. Every time. All the time!

We Listen and We Deliver!

Having completed over 15,000 projects since 1987, JMP has earned a reputation for delivering world class engineering solutions in core areas.

Our differentiation is founded on delivering engineering services and turnkey solutions that are backed by our Promise of:

1. Guaranteed Performance2. Exceptional Communications3. Radical Commitment

For us, it’s simple.


Problems We Solve

Quality

Throughput/Yield

Regulatory Compliance

Cost (WIP Inventory, IT Systems, Labor, Materials, Energy, Maintenance)

Time to Value

Risk – (Project Management and Change Acceleration Process)


Serving Clients Locally15,000+ Projects Completed for Global Customers

With 13 different business units, JMP services our national clients locally.

Canadian Locations:

• Burlington

• Cambridge

• Calgary

• London

• Montreal

• Toronto

• Information Division

• Smart Robotics Division

US Locations:

• Dallas

• Houston

• Lexington

• Philadelphia

• San Antonio


The JMP DifferenceUnique Execution of Combined Expertise

Extraordinary Customer Experience

• Guaranteed Performance

• Exceptional Communication

• Radical Commitment

First Priority – Customer Satisfaction

• Address customer issues daily, from employee to Executive Team

• Net Promoter Score (NPS)

Execution Excellence – All the time, every time!

• Project Management

• Change Management

• Risk Management

• Multi-Site Execution

JMP Promise

Operational Discipline

Project Execution

Methodologies


Rockwell Automation Solution Partner

Only company in the world that is CSIA Certified, RIA Certified and a Rockwell Automation Solution Partner

CSIA Certified Member (Control System Integrators Association)

Extensive best practices and benchmark program

Annual re-certification process

The ISO of the integration industry

Recognized as a “Best in Class”company by Control Engineering Magazine and Packaging Digest.

Numerous Technology & Product Certifications

Great Place to Work –four years running!

Commitment to ExcellenceContinually Redefining Best Practices


Key Components of JMP Project ToolsetRisk Log

Proactive risk definition

Mitigation strategies

Used throughout project

Project Management Stage Gates

Embedded Change Management Practices within Project Methodology

Project Execution MethodologyImprove Project Success, Adoption and Business Impact

Kickoff

Commitment level

Risk Assessment

Guiding forces

Same? Change?

Functional Spec

Current and future states

Design Reviews

Assess change log items

Closeout

Verify all project requirements were met

Stakeholders committed to success?

Post-Project

On-site support

Virtual support

Updates and optimizations

Refresher courses

FAT and SAT

Verify all aspects of performance are met

Stakeholder needs review

Change Management Log

Physical Aspects

Operational Aspects

Human Aspects

Issues Deck

Track open tasks

By customer, JMP, Sub-contractors

Assign responsibility

Lessons Learned

What worked?

What did not?

How do we improve for the next project?

Plan Execute Evaluate Closeout Support

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Energy Opportunity

Most industrial facilities are flying blind

Real time energy consumption is often not available or presented to those who can take action to minimize the cost of manufacturing

attributed to energy

Lack of historical analysis (data and information) at the point of consumption limits the effectiveness of targeted Continuous

Improvement programs

Capital justification for equipment upgrade and retrofit programs is difficult without the data and measurement systems in place

Energy costs are often just allocated across the facility and manufacturing departments masking true energy variances that exist every

moment of the manufacturing day.

What if there was an Energy Cockpit available for everyone ?


Energy Costs Impact by Industry

IndustryEnergy as a % of Direct

Product Cost*

Cement 24.5%

Alumina and Aluminum 21%

Petroleum Refining 21%

Iron and Steel 20.4%

Glass 14%

Pulp and Paper 8.8%

Metal Casting 8%

Brewing 3% to 8%

Metal Finishing 6.7%

Chemical Manufacturing 5.4%

Food Manufacturing 3.3%

Fabricated Metal Products 2.7%

Shipbuilding and Ship Repair 1.2%

Motor Vehicle Manufacturing 1.1%


Simple Visualization

No longer flying blind!


Energy Opportunity Real-Time Energy Usage

Is our HVAC running to target for this manufacturing cycle?

How much is it costing to run all the fans at the same speed? What is the right speed ?

How is this impacting my actual unit cost?

Why is it different than last time?

What about chillers, compressed air, dryers, process steam, furnaces and other energy consuming

assets?

Awareness of real time energy usage alone can drive a 5% cost reduction.


TAG LINE: “JMP Energy Management & Targeting Solution provides the basis for helping U.S. DOE Better Buildings Better Plants Challenge Partners meet their goals for energy reductions”

Energy OpportunityIncentives

Wouldn’t it be great to benefit from current government incentive programs, driving down our energy

costs and improving our energy stability?

How much can be saved?

What is required to support and administer such a program?

What about other utility costs and programs such as water, gas, steam?

Incentive programs can represent significant Program funding/matching!

https://www4.eere.energy.gov/challenge/

https://www4.eere.energy.gov/challenge/


AboutFood & Beverage Manufacturer

Overview: Meat Packer who is a vertically integrated processor of premium quality, fresh pork that has been in

operation since 1982. Their company is owned and supplied by a co-operative of 160 Southern Ontario family farmers.

Products are available at national and regional chains, and independent grocers.

Exporter of pork to over 30 countries around the globe, including: Japan, United States, South Korea, Philippines and Mexico. Consistency, attention to detail, and developing sound working relationships, have been paramount for international growth.

Processing plant has continued to expand with the last major expansion being completed in 2003; continued growth is an integral component of their business plan going forward.

Plant statistics:

Located in Breslau, Ontario, the plant has 700 employees and processes 24,000 hogs per week.

Federally inspected, and HACCP certified, with government inspectors on site at all times.

Capable of handling specialized product requirements and servicing niche markets and will create tailor-made solutions to satisfy their customers.

Dedication to quality and food safety in every stage of production – from the family operated farms to our modern processing plant. Meeting government requirements for food safety is their minimum standard, and their farmers and processing plant employees strive to go beyond.


The ClientFood &Beverage Manufacturer

The ProjectEnergy and Utilities Information System

The Challenge Need for data collection and

reporting of critical process control parameters across multiple areas of the production facility (displayed below)

Customer could not see what their current energy usage was by various assets, in real-time, down to the specific energy using assets Chillers, freezer, water,

electrical, HVAC motors, etc. Wanted to reduce energy and

utility costs through real-time energy use realization and collection

Effort required to examine Hazard Analysis and Critical Control Points (HACCP) data and ensure quality and food safety

Action Established a baseline infrastructure

for data collection and process analysis of readily available data points

Installed monitoring systems for 200 physical assets to collect real-time energy consumption data Rockwell FactoryTalk

VantagePoint visualization dashboard showing real-time energy performance and it’s target at the asset level

Rockwell FactoryTalk Historian for data collection and recording

Developed both Overall Plant Dashboards and Area Dashboard Screens, containing KPI information

Project ProfileReal-Time Data Acquisition and Energy Monitoring


Our Unique ValueJMP was chosen as the implementation partner due to our proven project methodology and our depth and breadth of knowledge across the following disciplines: industrial energy and utilities

management control systems information systems

The Results Quality Monitoring and

Improvements HACCP data monitoring

and reporting for food safety compliance including cooler temperatures

Monitoring of data points that affect the quality of the final product such as meat temperatures

Project ProfileAggressive Sustainability Effort Cuts Plant Utility Costs

Cost Reduction Monitor and record utility

consumption data to visualize time of day usage costs thus enabling production or scheduling improvements to reduce utility consumption

Waste tracking leading to process improvements to reduce waste

Process Overall Equipment Effectiveness (OEE) Improvements Improve OEE through lower

downtime Optimize process control settings Fault tracking to identify problem

areas and improve scheduled preventative maintenance

The ClientFood &Beverage Manufacturer



Plant Overview Dashboard


Cooler Trend

Cooler Trend

The Trend application provided with VantagePoint allows for quick display and comparison of data points. The Trend app can be accessed from the Navigation bar, under Tools. The first time Trend is selected on a client, it downloads a small file from the VantagePoint server. Once installed, data from the CMP model can be selected and dragged onto the display window. Trend allows for multiple points to be displayed. Settings are available for how the graphs are displayed, the time period which is shown, and if the data should be automatically refreshed.


Cooler Dashboard

Cooler Dashboard

The Cooler Dashboard displays data for all five Coolers. Specific Cooler and Time Period are both selectable parameters for this dashboard.Air Temperatures, Product Temperatures, Suction Temperatures, and Fan Speeds are displayed as line graphs over the selected Time Period. Spray Nozzle Activations are displayed as a bar graph over the selected Time Period.


Utilities Dashboard

Utilities Dashboard

The Utilities Dashboard displays data for both the Electric and Water systems. Specific Electric Service, Water Service, and Time Period are selectable parameters for this dashboard.

Electric Service Voltages, Electric Service Currents, Electric Service Power Factor, Electric Service Kilowatt, and Water Service Flow Rate are displayed as line graphs over the selected Time Period.


AboutFood & Beverage Manufacturer

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Overview:

JMP has been an engaged with this major brewery for over 10 years and has provided extended long-term embedded support, as

required.

170 years of brewing excellence and commitment to the communities where it operates.

With a portfolio of about 60 quality beers and breweries from coast to coast, they employ 3,000 Canadians across four major

market regions: Western, Ontario, Québec, and Atlantic.

JMP is committed to providing local support in London, Edmonton, and Montreal with a focus on strengthening the relationship

across Canada.

Plant statistics:

Packaging and brew expert, owning a large share of the Canadian market

Brews approximately 10 million hectolitres annually or 350 million bottles of beer.

Brewers of more than 60 different brands, brew masters combine leading-edge technology in packaging equipment and

operations, with the power of its worldwide resources to ensure the highest quality brewing ingredients, methods technology and

people are used in the creation of its fine products.


The ClientFood & BeverageManufacturer


The Challenge Bring common energy utilization

metrics to all plants to manage and reduce utilities costs

Deliver timely energy information to drive focused improvements

5 year energy target of $10 million cost reduction in utilities consumption through conservation and best operating practices

Action Multi-level reporting by utility

covering: Electricity, gas/oil, water, steam,

compressed air, ammonia, CO2, caustic

Energy data normalized to production volumes and seasonality

Visibility into consumption details driving energy conservation processes and culture

Identified significant energy conservation and cost savings opportunities

Monitored and tracked energy utilization and long-term process performance

Implemented in all five plants within one year from concept

Project ProfileEnergy Management


Our Unique ValueJMP was chosen as the implementation partner due to our proven project methodology and our depth and breadth of knowledge across the following disciplines: Industrial energy and utilities

management Control systems Information systems

The Results Continuously monitor energy

usage at each site Developed standard metrics and

site-to-site best practices sharing Calculated refrigeration, boiler

efficiencies, and CO2 collection for additional analysis

Larger plants realized payback within the first year of operation and achieved a national environmental award

Achieved world class benchmarks for energy conservation

Project ProfileEnergy Management

The ClientFood & BeverageManufacturer



AboutAutomotive Manufacturer

Overview:

Long standing customer of JMP (12 years)

First plant to make specific vehicles outside of home country

Plant statistics:

8,000 employees

3 million sq. ft.

Many disparate facility systems, for example: Air, Water, Heat, Cooling, Power


The ClientMajor Automobile Manufacturer


The ChallengeReduce the cost of energy and utilities across their production system.

Need for a comprehensive energy and utilities information management system to allow them to visualize, analyze and optimize the performance of the energy and utilities infrastructure:

Designed to collect data from across the sub-system

Provide reports, dashboards and other information analysis tools based upon location and need

System request driven by the requirements imposed by government entities in order to be eligible for incentive programs and grants

ActionWith the customer’s preference for Rockwell Automation in mind, an innovative solution leveraging the visualization and information modeling features from FactoryTalk VantagePoint software was used.

VantagePoint allows for advanced analysis of energy and utilities information by plant area and in context with data from production management and shop floor control systems.

FactoryTalk, VantagePoint, and FactoryTalk Historian SE were used to access the information, organize it, and provide tools for analysis, reporting and visualization of that data via the web.

VantagePoint was also used to generate trend charts, summary and tabular reports, and real-time dashboards.



This facility incurs an energy and utility bill of nearly $45 million annually. The client projects a double digit ROI on the overall investment on an annual basis.

System control and detailed system visualization provided via a distributed implementation of Rockwell’s FactoryTalk View SE SCADA platform and a Control Logix platform

Multiple third party gateways were used to connect the sensor and meter infrastructure to the information system

The base system includes hundreds of water, air, gas, electric and steam meters, with additional meters, sensors, systems and data sources to be added as the system evolves

Our Unique Value JMP was chosen as the

implementation partner due to our proven project methodology and our depth and breadth of knowledge across the disciplines of industrial energy and utilities management, control systems, and information systems

JMP was able to demonstrate the project management, exceptional communication and technical excellence required to help our client design their vision and secure the funding for a comprehensive energy and utilities information management solution

The Results The base system was accepted in October

2014. Individual energy and utility infrastructure

projects will be added to the systems in the coming months

Multiple examples of energy savings recognized and acted upon even before final system was accepted:

Capturing and acting on a “peak shaving” opportunity

The client projects a double digit ROI annually to combat an energy and utility bill of nearly $45 million

“

”



Automotive Manufacturer Project The Challenge

Considerations:

Energy consumption

$45 million annual utility expenditure

Historical data

Unable to validate invoices to actual usage

Capital spend justification

No measurement system in place

Energy cost allocation

9 major energy consumption areas

200+ metering points

Potential annual savings of 5-15% ($2-6 million)!


Automotive Manufacturer Project Initial Conditions

Limited monthly utility report

after the fact

Shop managers have no

visibility to real time utility

usage

Environmental effect on

production variability obscured

Non-production use unknown

You can’t control what you can’t measure.


Automotive Manufacturer ProjectAction

Leverage the customer’s

preferred platform technology

Complete engineering study

Metering:

Real Time data collection; load

historian with real-time data

Monitoring:

Define web dashboards, reports,

and query tools

Modeling:

Model energy usage for each

shop/area/asset


Automotive Manufacturer ProjectAction

Deploy Commercial Off-The-

Shelf software (COTS) as

platform technology

Why COTS and not custom?

Fast time-to-value

Scalability

Reusability

Lower project risk


Automotive Manufacturer ProjectThe Results

Increased energy awareness

and visibility

Provincial funding for >$10

million

Numerous capital projects

initiated

The initial engineering study enabled all of the above.


You can’t control what you can’t measure!

Metering

> 200 real time metered points

Monitor and Visualize

Web based reporting

Query capability

Targeting for Continuous Improvement

Modeling and contextualization of utility data

for each area by day for each variable

Predict and Prevent

Best Practices: Just because you can collect data,

should you?

Follow-up on top issues weekly to make

sure they are completed

Correct so they do not happen again!

Use data to predict and prevent!

Operational Excellence

Develop a Roadmap Today!


Automotive Manufacturing SystemArchitecture


Clients We’ve HelpedContinually Redefining What is Possible

If you had cereal for breakfast, drank a glassof water, drove to work, pumped fuel in yourcar, enjoyed a chocolate bar, potato chip orbrownie, had your child vaccinated, openeda package, relaxed with a cool beverage,visited an aquarium, watched an airplanebeing refueled, screamed down awaterslide, or watched the roof open onthe Toronto Blue Jays stadium, you’ve likelybenefited from a JMP solution!


Next Steps

Phase 1 – On-Site Energy Assessment

Survey current data infrastructure

Evaluate existing Energy utilization data

Identify areas for potential energy savings

Define additional data sources needed

Provide high level budgetary estimate

Phase 2 – Engineering Scoping Specification

Build a specification and scope document, if one does not exist

Highlight best course of action to start monitoring energy consuming areas

Define dashboard types your team will use daily, weekly and monthly

Phase 3 – Project Kickoff

As part of our Project Management process:

Weekly formal communication meetings and project updates

Project gate reviews conducted

Define training needed for proper operation, maintenance, troubleshootingand updating of the system for self-sustaining and maintaining the EnergyManagement Solution

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900D

Appendix


Energy OpportunityDon’t Fly Blind

Things to consider:

Real Time Energy consumption

Point of consumption historical data

Energy cost allocation

Justification of capital spend

What if there was an Energy Cockpit available for everyone?


Single physical server, multiple virtual servers

Connection to multiple plant floor PLCs

Historian collects and archives data points

Client PCs access

VantagePoint (reporting from Historian)

FactoryTalkViewSE (SCADA)

Automotive Manufacturing SystemArchitecture


Project Selection Process

Project Project Description Savings

Compressed Air – Blow off reduction Install new control system and 2 VSD screw compressors 2,000 MWh

HVAC refurbishment Install new HVAC controls, VSD’s on fans, overall BAS control system 2,300 MWh

Chiller system efficiency improvement Optimize chiller plant efficiency – install new control system, VSD’s on

pumps

4,000 MWh

Fuel cell Install 1.4 MW molten carbonate fuel cell, reclaim available heat 8,000 MWh

Utility monitoring and targeting Support update of utility monitoring system, develop targeting system TBD

Combined heat and power Install 3 to 6 MW of gas turbine and 1600 ton absorption chiller TBD

Solar wall (solar heating) Determine best location(s), HVAC integration for conserval solar wall 175 Km3

South paint steam elimination Reclaim heat from RTO to heat pre-treatment dip tanks and ASH reheat

coils

710 Km3

North paint steam reduction Install local HWB to heat pre-treatment dip tanks and shop HVACs 100 Km3


Reports accessed from main screen, broken down by plant, area, and utility type

Automotive Mfr. M&T SystemVantage Point – Reports


Automotive Mfr. M&T SystemVantage Point – Report Types


Automotive Mfr. M&T SystemVantage Point – Dashboards


Automotive Mfr. M&T SystemVantage Point – Sample Report (Overall Airflow)


Automotive Mfr. M&T SystemVantage Point – Sample Report (Zoomed by Time Airflow)


Automotive Mfr. M&T SystemVantage Point – Sample Excel Based Report


Server/client architecture

Access levels by login

Some control, mostly read only, real time data

Potential uses

Facilities – monitor systems, overall operations, control systems as required

Shop Manager – monitor current shop utilities usage (could display on Andons)

Facilities management – overall utility usage

Automotive Mfr. M&T SystemSCADA – Factory Talk View SE


Automotive Mfr. M&T SystemSCADA – Factory Talk View SE – Overview Screens


Automotive Mfr. M&T SystemSCADA – Factory Talk View SE – Overview Screens


Automotive Mfr. M&T SystemSCADA – Factory Talk View SE – Department Status


Automotive Mfr. M&T SystemSCADA – Factory Talk View SE – Shop Managers


Automotive Mfr. M&T SystemHVAC Controls Upgrade – SCADA


Automotive Mfr. M&T SystemHVAC Controls Upgrade – Scheduler

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Documents

CT237 Real-Time Energy Monitoring and Targeting Best ... · PDF file• Net Promoter Score ... Capable of handling specialized product requirements and servicing niche markets and