Digitalizacija in zagotavljanje

Program Kompetenčni centri za razvoj kadrov sofinancirata Ministrstvo za delo, družino, socialne zadeve in enake možnosti ter Evropska unija iz Evropskega socialnega sklada.

Digitalizacija in zagotavljanje

energetske učinkovitosti

proizvodnih procesov

Webinar, 28.5.2020

Predavatelji

Andrej Lazovič

Digital Industries

Factory Automation

Technical Sales Support

GSM: +386 (40) 740 835

[email protected]

Aljoša Doberšek

Digital Industries

Process Automation

Sales Engineer

GSM: +386 (51) 366 709

[email protected]

Rok Koren

Digital Industries

Digitalization Specialist

GSM: +386 (51) 681 455

[email protected]

2. Poglavje

Implementacija energetskega

managementa v praksi

Andrej Lazovič

GSM: +386 (40) 740 835

[email protected]

Predavatelj: Andrej Lazovič (040 740 835 )

Transparency and efficiency from machine to company

Management level

Data handling and

monitoring

Production level

Acquisition

Field level, e.g. drive motor

Plant and company-wide energy analysis

Directly in the field: Energy Meter

Standardized efficiency evaluation of machines

Simple and integrated energy data acquisition

ISO 50001 certified


Metering Data processing Visualization

Water Meter

Flow Meter

Current Transformer

FrequencyConverter

kW

kWh

(N)M³/h

(N)M³

kg(/h)

Piece count

4…20 mA

0-5 V

Counter reading

(abs.)

Energy values

(diff.)

Reporting

• Counter Read.

• Energy value

• Ø-Power/Flow

Correlation with

•States/Modes

•Op. Modes

•Production rate

•(Short-term-)

archive

EnPI

Benchmarks

Efficiency Analysis

Trends Analysis

0 15

5 10

Long-term archiving

Metering and Data Acquisition


Measuring types of energy maters

* Measuring Instruments Directive

Meters Metering incorporated in device

Electrical EnergyNon-electrical types of

energyElectrical Energy

Tip

merilnika:


Measuring of electrical energyApplication examples

*) current transformer

HMI

400V10 KV

*)

PLC Energy Meter

+PLC +

Periphery

AI / DO / DI

HMI

400V

Application

Energy Meter

Energy distribution Production machine

Measuring in control cabinets and in production


Tip 1

Rogowski-Coil

(instead of CT)

Flow meters with

Clamp-on-technologyDrives

Switch gear

Digital Input

Current

Transformer

Load

Load

Current

Transformer

Water Meter

Electricity Meter

(S0-Pulses)

Modbus RTU

Analog Input

Anergy Input


Nizkonapetostno stikališče:


Electrical Measured Values

Types of ConnectionMeasured Values

• 3P4W, 3 Phase, 4 Conductor• 1P2W, 1 Phase, 2 Conductor

+ 3P4W1, 3 Phase, (symm. load)+ 2P3W, 2 Phase+ 3 x 1P2W

Basic

Sta

nd

ard

• U

• I

• S/Q/P

• E

• f

• Power factor

• EE@Industry profiles

+ 3P4W1, 3 Phase+ 3P3W, 3 Phase+ 3P3W1, 3 Phase+ 3P4WI, 3 Phase (only for current measurement)

+ 1..40 Harmonics (U/I)

+ Voltage drop analysis

+ Overvoltage analysis

+ Overcurrent analysis

+ Sum current I1, I2, I3, IN

+ harmonic distortion

+ Amplitude balance U,I

+ cos(𝜑)

Hig

h F

eatu

re


Expansion of measuring infrastructure – current transformers

Nominal current

primary side60 A …150 A 50 A … 600 A 50 A … 1500

A

Nominal current

secondary side5 A 1 A/5 A 1 A/5 A

Accuracy

class

1 0,5/1 1/3

Nominal

load

1,25 VA

… 3,75 VA

1,0 VA

… 5 VA

2,5VA

… 10 VA

Current transformers are a special form of

transformers

… which have to be used where the expected currents

cannot be measured directly

(size, galvanic isolation)

Selection of current transformers

… should be dimensioned according to the expected

nominal current to minimize measuring errors

Accuracy

… all errors of the components in the measuring

system need to be considered for system

accuracy (transformers and measuring devices)

Short-circuit of current transformers

… the secondary circuit of the current transformer

should never be opened, if current flows in the

primary circuit (destruction/danger to life)



Management level

Data handling and

monitoring

Production level

Acquisition






ISO 50001 certified


The simple solution for Integration and Monitoring

Generationinstead of programming

Consistent

Information

VisualizationHMI

Archiving

AnalysisEnergy App

EasyIntegration

Measuring

Data

buffering

at PLC


Visualization


21

…

General requirements for a load management system

Active Load

Management

Production Ventilation Compressor Generator

Industry

Load management

system3

1. Avoiding load peaks

without influencing

production process

2. Automatic regulation

of the system

3. Response of the system to

feedback of the production

process


Time

Power consumption

Limit

Use case example:Load management at television broadcaster

Customer

requirements

• Using of existing measuring

points

and energy storages

• High availability

of the system

• Consideration of several

power infeed

• Extensions regarding

the integration of future

e-car charging areas

Big energy storages

for uninterruptible power supply


Load management

Visualization example

+Detail view per actuator- All relevant information at a glance

- Subsequent configuration possible

- Operation of the manual mode

+

Overview of the load management- Presentation of the previous and current period using a

triangle diagram

- Historical values of the infeed up to 7 days

- List of all actors including status and configuration possibility


Power supply

company

Production Cooling E-car charging

…

Why is it important to increase the grid stabilityfor production reliability?

Time

Power consumption

Grid limit

• Steadily increasing

number of energy

consumers in the

company (e.g. E-car

charging stations)

• High load peaks during

short times (e.g. during

lunch time)

• No available grid

for providing energy

Industry


Time

Power consumption

Limit

Power supply

company

Production Cooling E-car charging

…

Internal

energy supply

Managing energy consumers and producers

Active Load

Management

• Avoiding load peaks

by evening out the

load distribution

• Connect company

internal energy sources

• Holistic energy manage-ment

solution


Use case example – “E-car filling station” –Decentralized energy concept

Customer

requirements

• Consistent solution from

measuring device up to

the data visualization

• Load management for energy

consumers

• Visualization via web

user interface

Energy Management Software

Data acquisition and

load management

Data analysis

and reporting

Power supply company

infeed

Combined heat

and power plant

Photovoltaic system

Charging stationsEnergy Storage

Predavatelj: Andrej Lazovič (040 740 835 )Restricted © Siemens AG 2018

Peak load management

Live Demo

Page 67 March 2018 DF FA PMA APC



Management level

Data handling and

monitoring

Production level

Acquisition






ISO 50001 certified


Norms and standards alleviate our everyday way of life

efficiency evaluation for industrial

machinery is also possibleThe simple efficiency evaluation of

household appliances is already standard

This does, however, require

expertise and the right tools


Efficiency analysis of machines

Machine builder

Machine operator (End customer)

1. Local evaluation on the machine 2. Central evaluation in EnMPRO

Production

machineFactory OverviewLocal Analyses


Efficiency Monitor on Energy management system

At a glance! • Energy per status

• Energy productive / non-productive



Management level

Data handling and

monitoring

Production level

Acquisition






ISO 50001 certified


Energy Management AppSupported Functionality

KPI / EnPI

Energy Management App

Web Server Database Server

Data

Acquisition

Datapoint

Configuration

KPI

Calculation

Visualization

Documentation

Acquisition

SQL Server


Energy Management AppEasy entry for standard applications

Save time by

avoiding additional

configuration

through predefined standard

templates for reports

PRO

Simple, system-

independent access

through intuitive web engineering

Clear presentation of

the most important

key figures

through simple and

understandable dashboards

Fast calculation of

KPIs

by formula editor, no programming

necessary

Can be used in any country

thanks to the availability of web engineering in six languages


Energy Management AppDetailed analyses and cross-location access

Analysis of measures

including target/actual

comparison & follow-up

through action planning and tracking

PRO

Individually and user-

specifically adaptable

through definable KPIs and

comprehensive reports

Cause-based

invoicing

of energy costs per piece through

batch & material analysis

More efficient energy

purchasing

through forecasting tool for long-

term planning

System-independent integration of analysis

data

easy transfer of data through file upload


Energy ManagementScalable


Energy Manager App

Mobile

Corporate Wide Energy Management

Plenty of interfaces

Manual others… WinCC / PCS7 / S7

ASCIIFTP

OPC UADA / HA

Modbus TCP

PLC

Connection

ERP e.g. SAP

xml csv

PLC

• Temporary local storage of data

• Data buffering in case of communication failure

• Data pre-processing and preparation (compression, …)

DesigoCC

OLE-DBODBC

Energy Acquisition Component per site

ModbusM-BUS DB AL DI

RTU

ModbusPROFINET PROFIBUSTCP

ISO50001

TÜV OPCUA


Electrical Energy

Gas

Compressed air

Cold water

Hot water

Corporate-LAN

Full Client

Existing Office-PC

, Edge, Chrome, Safari,

Firefox

Ethernet (TCP/IP)

Ethernet (TCP/IP) Process - LAN

WEB Clients

Router/

Firewall

3 3

RTU

TCP

Gas

WAN/

LAN

Data

Acquisition-

component

Existing Office-PC

Edge, Chrome, Safari, Firefox

Electrical Energy

33

33

Data Acquisition

PLC, AI Energy-Meter, DI

SCADA

Site BSite A

Router/

Firewall

Energy ManagementDistributed Data Architecture for additional locations + Cloud

Production

data server

(OPC UA)

(Acquisition-

component)

Server

Server

SQL Server

Mobile APP

MindConnect-

Lib

ClaudvApps


Live Demo


Energy Management in claud ?

Claud ?

Benefits

▶ Energy transparency supporting ISO 50001

▶ Flexible KPI definition and user specific dashboards providing a holistic view

about the energy consumption and can be used to derive energy efficiency

measures

▶ Transparency about energy costs, consumption and CO2 Emission from the

machine level to your sites worldwide

▶ Get the most valuable information for precise decision-making to optimize energy

efficiency

Features

▶ Out of the box energy media analysis (consumption, costs, CO2 Emission)

▶ Flexible dashboard configuration with detail views for fast analysis

▶ Support of different widgets (charts, pie, gauge, Sankey, heat map) to visualize

energy performance indicators

Industry focus

Cross industry based on flexible dashboard and KPI calculation

DI FA


Energy Management AppDashboards - Transfer data to information

See where

energy is

consumedSee when

energy is

consumed

Benefits

Using custom dashboard with energy

related widgets to transfer data to

information

• Sankey Diagram provides an overview

about the energy flow → see where

energy is consumed

• In the heat map the value is

represented as color. → see when

energy is consumed.

• Additional Widget types like Gauge,

Pie Chart, Value, Chart are used to

display KPIs in a way that measures

can derived immediately.


Energy Management appOut of the box analytic

Energy

over time

Detailed information for each widget in

the dashboard

• The diagram view provides detailed

information in a configurable

resolution (e.g. 1h) to see any

anomalies like peaks,..

• Statistic view provides a histogram for

each parameter including the statistic.

(min, max, average, median, standard

deviation and sum)

• Regression view provides the

possibility to display the data in a x-y

chart including a trend representing

the plant characteristic.

Statistics

See relations

and detect

anomalies

Benefits


Transparency on machine level

Transparency about energy

consumption in the different machine

states (Working, Operational, Standby,

Off,..)

KPI representing the operation of the

individual machine.

• Valuable energy (Working / Total)

• Losses caused by inefficient

machine operation

This is the

savings potential

Degree of efficiency

Red: Energy

consumption in

idling mode

= Energy wasted

Green: Energy

consumption in

working mode

= Energy used

DI FA

Benefits


Energy transparency for all levels in the factory

Simple configuration providing with a high

value

• Details about each consumed media

in the chart (consumption, costs, CO2

and these KPIs per unit)

• Summary of each media display the

most important KPIs (consumption,

costs, CO2 and these KPIs per unit)

• The donut charts represents the total

costs and the total CO2 emission and

the distribution to the several media

Detailed energy

consumption per

medium (water,

gas, elecricity

Summary

per media

Benefits


Flexible KPI definition using KPI Types or define type less KPIs

KPI based on a KPI Type Type less KPI

Templates for

multiple usage

of KPIsExcel-like

formula editor

DI FA


Questions and Answers

Digitalizacija in zagotavljanje

Documents

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