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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

WW OPS-6 Transform Energy Data into Operational Information with Wonderware Corporate Energy Management Bill Schiel

Director- Global Business DevelopmentRudy Engert

Business Development Manager – CEM & W/WW

Christian-Marc PouyezProduct Manager – Intelligence & CEM

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Agenda

CEM problem statement & definition, opportunityCEM product description• Integration with ArchestrA System PlatformDemo• CEM, Intelligence, Workflow, Reports,…Business cases Roadmap

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Definition Of Corporate Energy Management

What is CEM?"CEM" refers to sets of actions that move accountability for energy outcomes to upper levels of the firm. With CEM, energy is no longer the sole responsibility of plant managers and engineers; in fact, CEM programs are designed to involve many areas of business activity, such as accounting, marketing, and others that were not traditionally concerned with energy. Bringing corporate-level attention and management into the picture helps to ensure enterprise-wide opportunities are explored.

From US Dept of Energy: http://www1.eere.energy.gov/industry/bestpractices/corporate_energy.html

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CEM is an *EMS Designed for Manufacturing

• Specified by the Invensys voting member of ISO 50001 US TAG• A clean-sheet design, a configurable application• Intended for use by manufacturing and heavy industrial operations, but

also applicable to any energy consuming enterprise• Bridges energy use data and manufacturing operational data• The only product on the market that produces real-time Energy

Performance Indicators for Intensity• Closes the loop on information through an integrated workflow component

that drives accountability

* EMS is Energy Management System

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CEM and Enterprise Control for EnergyBig Picture Concept:

Solve a corporations energy management initiative for ALL energy consuming assets:

• Factories and Plants• Research centers• Distribution Centers and

Warehouses• Offices

Approach:• Use CEM, SP, EMI, AWF, and

other components for a total solution

• Provide Local level detailed information for day-to-day operations

• Corporate level reports and analysis for weekly, monthly use

• Energy Consumption used for Activity Based Accounting for Energy-ABC4E

• Energy Consumption fed to Green House Gas and resource reporting

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Energy Management is a Straight-Forward Concept

Why do manufacturers and industry have energy management initiatives?

Financial Benefits – Spend less: Reduce Energy-Spend as an indirect cost – Use less: Reduce Energy Cost in COGS (materials+labor+energy)– Avoid unplanned cost: energy-use penalties (demand charges, surcharges)– Resource Availability: Plan for, and respond to, unreliable energy supply

(brown-outs)Corporate Responsibility

– Triple Bottom Line: Profit, People, Planet – Demanded by their customers (standards eg: Walmart) – Demanded by their governments (Regulations)

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What is Return on Investment?

We Need to know: – Annual and Monthly

Consumption Spend on Energy• Example: Annual $240,000,

monthly average $20,000– Surcharges for excess total

usage and demand penalties• Example: 10 charges per year,

total $50,000– Total Annual Spend $260,000

What CEM can do:– Decrease consumption spend

10-30% • 10% of $240,000 = $24,000

year• 30% of $240,000 = $72,000

– Avoid Surcharges• ½ avoided = $25,000

– Total Decrease of $49,000 to $97,000 year

Example for Electricity

Investment is Software+Hardware+Services and will vary with EVERY projectbased on the application and the state of the energy metering infrastructure

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Key Concept: The Journey

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Ad Hoc Awareness Managed

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Ad Hoc

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Ad Hoc Awareness Managed

• The “Low Hanging Fruit” is addressed– Energy efficient lighting, occupancy sensors– Variable speed drives installed– Low flow water fixtures installed– Spot check and manual reporting of energy/water usage monthly or weekly

• Challenges– Did it work?– Is it still working? “Low hanging fruit grows back”– Are there unintended consequences? – What if Roberto leaves?

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Evidence

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Awareness

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Ad Hoc Awareness Managed

• The organization learns about energy use and adapts– Sub-metering gives more granular usage– Experiments occur… what if we did this..? Kaizen in action!– Investments are made knowing ROI can be determined– Weekly, Daily, Shift reports become part of normal operations management– Real-time notification of success, deviations, failures

• Challenges– Demand for more meaningful data, related to what people are responsible for– Knowing deviations and failures is good, but can we prevent them? – Are there unintended consequences?

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Managed

Ad Hoc Awareness Managed

• Energy Management is an organizational competency– Everyone knows how energy usage and deviation effect financial

performance– Energy is managed as a variable cost and used by ERP for planning– The benefits of the energy management are sustained year after year– Automation is in place to prevent deviations– Smart Grid becomes a competitive advantage, bring it on!

• Challenges– Change– Continuous improvement

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CEM Product Description

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Context Transforms Energy Data to Energy Information

CorporateEnergy

ManagementApplication

(CEM)

Automatic•Direct to Meters (also wireless)•Meters thru PLC/DCS•RTU from remote sites•Building Management System•Utility Interval Readings

Mobile• IntelaTrac• Mobile Data Collection

External Context•Weather- Current, Forecast•Utility Rates•Demand Response Signals from Grid

Internal Context•Operational Events from automation and MES•Asset State from automation•Order, Batch, SKU

Energy UsageData

Usage Context

Corporate KPI

Asset Management

CMMS

ERP/MES

Energy Metrics

Work Request

Energy Usage

InTouch HMI• Real-time view of

energy usage• Real-time KPIs

Web Portal• Run Pre-

configured reports

• Analytics, Trends

Production Worker Energy ManagerController/Accountant

CorporateEnergy Manager

Intelligence- EMI for Operations

Energy Information

Advanced Analysis and Simulation

Rich Data

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Energy Management Application Components

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System Platform

IAS Historian WIS

DAS- PLC

DAS- Modbus

DAS- BACnet

BuildingManagement

System

Meters for:• Electric

Power• Compressed

Air• Steam• Water• Gas• Chilled

Medium

CEM

EnergyDatabase

BACnetLonWorks

inTouchfor real-timeview of energyusage

WIS for usagereports

Intelligence-EMI for KPIs

PLCDCS

Online ConnectedMeters

WorkFlow

SmartGlanceMobileReporting

OfflineMeters

IndustrialAutomation

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CEM Meter Objects

Meter Objects

•Manage Device (meter)•Configure & Apply Rate Schedule•Read meter at intervals•Collect data values to add context to reading•Collect additional data from meter and send to Historian•Store and forward

CEM Engine Service• Single Connection to

Energy Database• One per Engine• Tested with 500 meters• Throttle DB access based

on CPU

Energy Database

Historian

Energy Usage Transactions

Energy Data Points

ArchestrA InfrastructureAnd I/O Drivers, Alarms

Accept External Rate Schedule

Makes Dumb Meters Smart!

AlarmsMeter Related Alarms

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CEM Event Objects

Event Objects

•Triggers defined and monitored•Assign meters to relate to event•Trigger meters to read•Collect data values to add context to event (lot ID, process values, etc.)•Collect additional data from meter and send to Historian

CEM Engine Service• Single Connection to

Energy Database• One per Engine• Tested with 500 meters• Throttle DB access based

on CPU

Energy Database

Historian

Energy Usage Events

Energy Data Points

ArchestrA InfrastructureAnd I/O Drivers, Alarms

PLC Registers, Database queries, MES objects, etc.

Examples of Events

• Production Order• High Flow• Equipment State• Shift

Alarms

Event Related Alarms

AlarmsEvent Related Alarms

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CEM Data validation/editing

• Offline mode• Data Editing• Interpolation of gaps

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CEM 1.5 Release: November 2012• Performance for 30,000 meters• Wonderware Intelligence Model and content for

CEM• Auto-interpolation of Offline data• Reports improvement• Billing Report

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Performance

Ensure performance for 30,000 meters for:• Configuration (Hierarchies)• Runtime (define architecture platforms/engines)• Visualization (Summary display)• Reporting (parameterizing and execution)• Editing (CEM Web App)

Provide a Deployment guideAssumptions:

• Single galaxy• 3 years of data @15 minutes recordings

CEM 1.5

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Intelligence for CEM• Self-Service access to CEM data. Enable end-users to:

• Do their own analysis of CEM data• Build their own reports/dashboards on CEM data

• Put CEM data in context with other sources (MES, Historian, alarms, etc.)

• Quick time to value with pre-defined content

CEM 1.5

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CEM Reports

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WonderEnergy Demonstration

• A simulated Brewery• Consumes electricity, gas, and water to brew beer• Underlying simulation to “operate” the brewery• Shows real-time and historical information• Used to demonstrate concepts and features

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CEM Use Cases

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Use Cases

1. Food and Beverage Plant2. Large Campus3. Central monitoring of distributed sites

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Food and Beverage Plants

Single Plant- Stand-aloneMultiple Plants- 9 Plants on one systemGlobal Rollout- Dozens of plants

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Large Campus

Example 1: Combined Building Automation and Energy ManagementExample 2: Energy Management with Future for other applications

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Central Monitoring of Distributed Sites

Example 1: 2000+ Distributed SitesExample 2: Central Reporting from global locations

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Energy Management Scenarios Enabled by Workflow Peak demand charge avoidance

Reduce load to avoid charge Automated Demand Response in complex operations

Day ahead- opt in/out Day of- execute, recover

Co-Gen Make vs. Buy When wholesales prices for gas give better value than electricity

Energy usage based maintenance Detect plugged filters, failing motors and equipment Notify maintenance people and CMMS

Energy data collection system not working properly Notify maintenance to investigate and fix Notify Energy Manager that data gaps exist

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CEM Roadmap

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CEM 2.0 - Ideas

CEM 2.0

Target Tracking

VEE

DB Mainte-nance

Diag-nostics Tools

Config. Produc-tivity Meter

Manage-ment

Demand Response

Voice of Customer Program

New ideas

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Target Monitoring

Target Definition: energy measure, reference period or event, meters, minimum & maximum, deviation,

One or more target by meter, event Input of targets by: Input Source, File, Database object (similar

to rate)Target tracking: inequality, CUSUM, trend, ArchestrA scriptTarget tracking enabled/disabled at runtimeAlerting: Alarm, email, IM, Workflow

CEM 2.0

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Validation, Estimation and Editing (VEE)

Option to auto distribute energy usage across offline intervalsEdition of offline recordset, with auto linear interpolationCompute deltas and costs upon entry/edition of dataAuto load offline meter data from a folder (operate as RTU)Audit log for edition of valuesEstimation of values while meter is offline:- by linear extrapolation- Custom script

CEM 2.0

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Meters - Miscellaneous

• Allow virtual meters to have offline child meters• Allow for an Historian input source for meters• Meter Replacement

- Additional MetaData: serial number, installed date, calibration, etc.- Counter value override- Allow for non-recording mode

CEM 2.0

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Diagnostics

• Compare Galaxy with CEM Database• Better error messages in ArchestrA logger, with identification of

source of problem.

CEM 2.0

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Database Administration

ArchivePurgeRestore

CEM 2.0

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Configuration Productivity

• Create strings automatically with default options when defining configuration items

• Do not require meta-data when defining a folder• Pre-defined configuration items upon fresh installation (meter types,

manufacturers, models, units, etc.)

CEM 2.0

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Demand Response (stretch goal)

Demand monitoring object, with target (re-use meter object?)ArchestrA Symbol in support of demand response

CEM 2.0

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For more information on CEM• Product Website: www.wonderware.com under Products• eLearning on training.wonderware.com• Business Development: bill.schiel@invensys.com • Sales: rudy.engert@invensys.com• Product Manager: christian-marc.pouyez@invensys.com• Product Marketing Manager: kelly.kunkle@invensys.com