energy management from siemens

Energy Managementfrom SIEMENS

siemens.comUnrestricted © Siemens AG 2016

23-06-2016

Unrestricted © Siemens AG 2016 Sachin Soni / DF FA AS

Challenges for the industry are growing worldwide

Siemens has the perfect answers to all the challenges of our customers in the manufacturingindustry

• Shorter innovation cycles• More complex products• Larger

data volumes

• Energy and resource efficiencyas key competitive factors

• Individualized mass production• Volatile markets• High

productivity

Strengtheningour customers’ competitiveness

Increasing efficiencyEnhancing flexibilityReducing the time to market

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Energy Data Management

Actual hurdles to overcome pain points

Missing transparency1

Heterogeneous infrastructure2

Manual data collection3

No real time data4

No Benchmarks6No cross-media and inter-divisionalmetering and reporting7

Manual reporting5

Actual situation

Standardizedapproach

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Energy Management vs Energy Data Management

Energy Management

Energy Services

Services for optimization along thewhole energy value chain, from theproduction of energy up to theconsumer.

Energy Data Management System

Technical system (hw, sw) for thecollection, analysis, documentation andvisualization of energy data as well asregulation and controlling of energyconsumption in plants and buildings.

Energy efficiency means re-ducingenergy consumption without having toreduce the use of energy consumingplants and equipments.

Energy Efficiency

EM enables companies to determine, improve and analyze systematically and continuously their energy consumption.Within this optimization process economy as well as technical and legal aspects have to be considered.

Energy Management System (ISO 50001)

Standard ISO 50001: Energy management systems – Requirements with guidance for useProcess to “manage” energy topics systematically and sustainable. (implemented like ISO140001/ISO 9001 standards)PDCA cycle: Plan – Do – Check - Act

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Energy Data Management – Electrical as well as nonelectrical parameters.

Energy Media

ƒElectricity

ƒGas

ƒSteam

ƒPressure

ƒCompressed airAuxiliary process

ƒTransport; storage

ƒDelivery, shipment

ƒWaste water preparat.

ƒCompressed Air

ƒCentral cold, heat …

Energy Data Management System to support plant wide energy management according to ISO 50001

Energy Supply

ƒLocal Energy-production

ƒEnergy- purchase

ƒPower, Gas,Oil, Diesel…

ƒContract type

ƒEnergydistribution

Production process

ƒDrives

ƒWater

ƒHVAC

ƒCompressedair

ƒLine-Metering

ƒReports

ƒProductionKPI

ƒMachines

ƒEquipment

ƒProcess

OutputƒCO2 emissions

ƒWaste heat, steam

ƒWaste water

ƒPower

ƒHeat ...

Building

ƒIndustrial building

ƒOffice building

ƒInterface to BMS

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Unrestricted © Siemens AG 2016Page 8 Sachin Soni / DF FA AS

… energy costs are a significantcost factor in production

… to achieve the targets,legal measures are taken

… energy efficient production is akey marketing instrument

UN Climate Change Conference 2015Paris

Limitation of the globaltemperature rise

Electricity prices 2000-20151

Germany, industrial

Annual riseof electricity price (Ø ‘00-‘15) 2°C

Opinion poll2015

A green image is key to thepurchasing decisions for amajority of those polled259%

SIMATIC Energy Suite with TIA PortalMotivation for Energy Management

ImageEnergy costsLaws andclimate protection

Corp. Responsibility

1 Prices including taxes, source: statista.com (Link); 2 Source: E.ON survey 2015 ( (Link)

10%

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Production-integrated Energy ManagementEnergy Management as integrated element on all levels

FieldLevel

Control Level

EnterpriseLevel

ManagementLevel

OperatorLevel

ERP PLM

MES

SCADA

Tota

llyIn

tegr

ated

Auto

mat

ion

Energy Data Management+ Dashboard, Reporting, Planning+ Controlling (EnPI / EEnPI)+ Standard Templates for Import

Line-Monitoringincl. Energy Management

+ Machine-oriented EnPI / EEnPI+ Standard PDI on SCADA level

Integrated Energy DataAcquisition(all energy types)

+ Energy consumption & machine status+ Integrated metering

Energy Management on all levels

Machine-orientedEnergy Management

+ Machine “Ready for Energy Man.”+ Standard PDI per Machine

PDI = Process Data Interface

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OverviewEnergy Management with SIMATIC

reporting

planning

purchasing

visualization

archiving

Limit-Monitoring

compression

Acquisition

communication

Energy- Management overall system

( Energy Suite )

B.Data (Energy Manager Pro)Energy

purchasing /planning

Energycontrolling

Reporting /Monitoring

Achivement

Loadmanagement

Visualisation

data processing

Energy acquisitionFi

eld

leve

lPL

Cle

vel

Ope

ratio

nala

ndpr

oced

ural

leve

lm

anag

emen

tlev

el

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Overview – Energy Management with SIMATIC

Metering - collect yourEnergy data

Measuring Monitoring

Transparency - displayand exam your Energy

Supervising

Analyze and controlyour Energy

Managing

Manage corporateEnergy consumption

ET200-Energy meter, SIRIUSSIMOCODE, SENTRON PAC, …

S7-1200, S7-1500, S7-300Basic Panels, Comfort Panel, …

TIA Portal ,SIMATIC WinCC V7, PCS7,SIMATIC Energy Suite

Metering Concept Entry Solution

TIA PortalWinCC V13, STEP7 V13

SIMATIC EnergyManager Pro

Process & Factory Solution Energy Management System

Machine / Field LevelMachine / Field Level Machine / Field LevelMachine / Field Level Control / System LevelControl / System Level Management LevelManagement Level

S7-300, S7-,400 S7-1500, Industrial PC

Energy Analytics

Master the basics ofenergy management

Transform your energy datainto energy knowledge

Siemens Energy & Environmental Services

Onsite solution- Energy Management with SIMATIC -

Onsite solution- Energy Management with SIMATIC -

Managed Service- Energy Analytics -Managed Service- Energy Analytics -

•

•••

• Operate an own energy datamanagement system and profit from fullflexibility

• Access to complete software• Software is installed at customer‘s site• Licensing costs – onetime payment,

Software-Update-Services possible

Complete flexibility through

•••

•

• Energy data management as a service• No access to software, B.Data web viewer• Software is hosted outside of customer‘s

site• Capex to Opex: Payment of monthly

service charge depending on selectedservice package

No internal experts are necessary

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Energy Management with SIMATICElectricity Metering

SIMATIC ET 200SP AI Energy Meter&

SIMATIC S7-1200 SM 1238 Energy Meter

Feature / Function τ BenefitsSIMATIC-based metering(3-phase)

Savings through integration in theAutomation (TIA)

Used along with other ET 200SPmodules DI / AI / F / …

One system for everything

Up to 60x ET 200SP AI EnergyMeters per line

Space-saving in cabinets

Support for current and voltagetransformers

Wide range of use

Accuracy class 0,5 High accuracy

Remanent meter reading storage No value loss due to supply voltagefailure

Up to 3x users (single-phase) perEnergy Meter

Savings

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SIMATIC B.Data (Enegy Manager Pro) – for corporate requirementsOverview per click of mouse – tailor-made for corporate structure

Site 3

FacilityManager

Management Procurement

Monitoring

Measures

Site 2

ProductionManagers


Monitoring

Measures

Site 1

EnergyManager


Monitoring

Measures

Headquarter

Corporate EnergyData Management

CFO

CEO

Energy Manager

Regional viewCorporate view

B.Data Client

B.Data Database

SAP

Web Clients

Energy Planning

EE measures (Corp)

Reports (Corp)

WAN

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SIMATIC B.Data (Enegy Manager Pro) – Data collectionInterfaces covering all relevant sources

B.Data

data baseManual

Mobile

ODBCConnector

ASCII

OPC Client

PCS 7/ WinCC/S7

XML

ƒ Automatic data collection

ƒ Mobile data collection

ƒ Manual data entry

ERP

others …

csv

Communication with almostall systems possible

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SIMATIC B.Data (Enegy Manager Pro) – Web-ClientsDouble-check plant efficiency from everywhere and at anytime

Apple’s Safari

Firefox

Windows Internet Explorer

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Reduced CostsFlexible integration saves investment

As part of SIMATIC-platform As add-on for installed base

Field Level

Management Level

Operation Level

Control Level

MES

SIMATIC PCS 7 / WinCC

SIMATIC S7 SIMATIC HMI

Sensors Actuators

SIMATIC B.Data

Field Level

Management Level

Operation Level

Control Level

SIMATIC B.Data

Autom.SystemsAutom.

SystemsData

SystemData

System

PLCPLC

SIMATIC S7

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3) Easier Energy Management2) Enhanced energy purchase1) Improve efficiency

SIMATIC B.Data (Enegy Manager Pro) – for site/production requirementsCovers all requirements in compliance with ISO50001

Optimize day-to-day business

EnergyEfficiencyMeasures

ForecastTariffVerification

EnergyControlling

EnergyMonitoring

ƒ Energyconsumptionoverview

ƒ Discover energy-guzzlers

ƒ Support for loadmanagement

ƒ Identify relevantconsumption

ƒ Improve stand-by-operation

ƒ Discoverpotentials

ƒ Verify targetfulfillment

ƒ Benchmarking

ƒ Target valuetracking

ƒ Correlationbetween costsand production

ƒ Tariff simulation

ƒ Identify max.consumption perperiod

ƒ Identify max. powerper period

ƒ Selection ofsuitable contracts

ƒ Bill verification

ƒ3x methods:a)Regressionb)Days/shiftsc)Prod/Batch based

ƒBasis for energytrading

ƒ Improved energypurchase

ƒForecast deviations

ƒBasis for energytrading

ƒReporting- Management- Energy Manager- Personnel(Production, …)

ƒ Tenants billing

ƒ Environmentalreporting

ƒ Track GHG-emissions

ƒ Trackimprovements

ƒMeter Management

ƒMeasuresManagement(Basis for audit)

ƒ Trackimprovements

ƒ Value substitutingmethods

ƒMan. data entry

ƒ Engineeringoptimized forEnergy Managers

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Benefits of EEnPI with SIMATIC B.Data• “Reason tree” provides more precise indication of

optimization potential• Energy efficiency evaluation of machines analog to

OEE performance model

Production-integrated Energy ManagementEquipment Energy Performance Indicator (EEnPI)

Reduction of non-value-adding energy consumption correlates with higher productivity

EEnPI

Productive

Quality

Performance

Availability

Overallconsumption

Energy consumption (e.g. kWh; kWh/to)

• Change over• Mal-function• Stand-by• Missing part

• Velocity

• Rejects• Waste

Value-adding Non-value adding

Qua

lity

loss

es

Per

form

ance

loss

es

Ava

ilabi

lity

loss

esEnergy Distribution

Normalized Production 3000 MWhPerformance losses 60 MWhQuality losses 340 MWhDisturbance losses 200 MWhHeating 200 MWh

* Week values

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Energy management integrated in automation… Energy transparency already during production... Energy and production data - simple combination

1.

Investment protection… Integration and continuous evolution with SIMATIC TIA-Portal… use of standard components in HW and SW… high data integrity with buffering in S7 and archiving in S7, SCADA

SIMATIC Energy Suite in TIA PortalCustomer benefit – End customer

Economical…reduced project costs through integrated energy metering and simple

engineering…one plattform for automation and energy management

3.

4.

Scalability…from production machine up to factory wide energy management…smooth link to SIMATIC Energy Manager PRO and SIMATIC HMI /

SCADA2.

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SIMATIC Energy Suite in TIA PortalCustomer benefit – System Integrator

Investment protection...reduced project risk with energy management integrated in SIMATIC

TIA Portal (compared to customer spec. solution)…use of standard components in HW and SW with worldwide

availability

1.

New business opportunities…Energy transparency in production... Added value through intelligent combination of energy data with

production data…enhanced customer potential through scalability from production

machine up to factory-wide energy management system

2.

3.

Competitive advantage through engineering efficiency…simple, intuitive engineering in TIA Portal…high flexibility to integrate different energy types and devices…Visualization in SIMATIC HMI / SCADA…smooth link to SIMATIC Energy Manager PRO

1.

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Investment protection...Energy management integrated in SIMATIC TIA Portal to assure

continous evolution…use of standard components in HW and SW with worldwide

availability…one engineering tool for automation and energy management…no specific (energy management) knowhow…global support (24/7)

1.

SIMATIC Energy Suite im TIA PortalCustomer benefit – Machine builder

Competitive advantage and new business opportunities…Energy efficient and –transparent machine as competitive advantage...Provision of energy data as value add (“Ready for Energy

Management”)…Conformity !

Offer today to comply with tomorrow!

1.

2.

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Energy Data ManagementSummary of Benefits

µ Increased energy consumption- and cost awareness

µ Prove of sustainability and green production

Awareness

µ Transparency on energy & media consumption, costs,

µ Allocation to consumer and cost center

µ Predictability and target controlling

µ Improved planning reliability and basis for decision making

Transparency

µ Improvement of total plant efficiency

µ Overview of optimization potential

µ Tracking and reporting of efficiency projects

Energy Efficiency

µ Support of ISO 50001 process

µ Sustainability reporting

µ Reports for quality audits

Meet Legal Standards

µ Integration in existing systems & Scalable solutions

µ Integration of existing measuring equipment

µ Seamless concept (Totally Integrated Automation)

Sustainable Invests

µ Reduced energy costs due to reduced consumption

µ Improved procurement conditions due to better predictability(Energy tariff model optimization)

Savings

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Selected Reference – Global references for B Data

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EDMS References in India

ƒ Manual energy data collectionis replaced by automation.ƒ Manpower requirement for

collection of energy data isoptimized now.ƒ Transparency of Cost and

consumption of Utilities.ƒ Reporting features of B Data.ƒ Easy integration of existing

energy meters with automationsystem.ƒ RT data for energy parametersƒ Basic energy consumption

Reportsƒ Easy Cost-analysis of every

utility.ƒ Total energy management by

Consumer-level Cost analysisof all production blocks.

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Thank you very much!

Sachin Soni

Siemens Ltd.RC-IN DF FA BD

Thane Belapur RoadThane 400601, India

Tel.: +91 22 33265841Mobile: +91 9004399355

mailto:[email protected]

siemens.com

energy management from siemens

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