Plant Energy Performance

Smart Operations Workforce Empowerment Real-time Profitability Smart Design & Engineering Asset Performance Investment Continuity Safety Cybersecurity Regulatory Compliance Energy Efficiency Environmental Sustainability Business Transformation

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Important information The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.

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Failure to observe this information can result in injury or equipment damage. © 2019 Schneider Electric. All rights reserved.

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1 – Introduction

Table of contents 1.

Introduction

5

2.

Customer challenges

7

3.

4.

2.1.

What are the customer challenges?

7

2.2.

What are the values of the solution?

8

2.3.

Glossary

8

Solutions overview

9

3.1.

Solutions presentation

9

3.2.

Main functions

9

Solution Architecture Description

15

4.1.

EcoStruxure Plant Architecture

15

4.2.

Architecture Dataflow

16

4.3.

Architecture Components Description

17

5.

Solution use case example

25

6.

Appendix

30

6.1.

Glossary

30

6.2.

Reference Documents

31

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1 – Introduction

1.

Introduction Industrial companies consume the most energy in the world and plant managers are experiencing greater challenges than ever before due to soaring energy costs as well as increased pressure from government regulation and compliance.

Energy management is no longer just an intellectual debate. It is a critically conditioned action, spanning as it does across the broad spectrum of energy – generation, transmission, distribution and consumption. The compelling needs of meeting increasing energy demand while reducing our carbon footprint can only be met through smart solutions and technologies that deliver intelligence, connectivity and efficiency.

To help our customers make the most of their energy, Schneider Electric has developed solutions for energy management and provides an extensive and comprehensive range of proven, innovative and intelligent energy management product offers. Our Plant Energy Performance solutions are the window to your digitized power network. They leverage IoT connectivity and distributed intelligence, provide the flexibility and adaptability needed for today and for the IoTenabled future. As power grid technology becomes more dynamic, systems more complex, and regulations more challenging, our solutions bring unique new capabilities that make it simpler to help protect people and assets, keep operations running, and save time and money.

Figure 1: EcoStruxure architecture

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1 – Introduction The energy management solution is aimed at industrial customers: 

Already using process automation and looking to add energy management on top of their existing plant process controls.



Implementing new energy efficient production that integrates process automation and energy management.

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2 – Customer challenges

2.

Customer challenges

2.1.

What are the customer challenges?

It is predicted that the world’s energy demand will double by 2050, and over the same period, the world’s CO2 emissions need to be halved. Therefore, as the cost of energy inevitably increases, customers will face huge challenges to manage energy costs, regulations, and energy efficiency.

Thus, major challenges facing our customers are increase production, reduce the energy footprint, and be able to easily monitor and analyze in depth the whole plant energy consumption to optimize the process.

2.1.1.

Better master electrical energy consumption & reduce cost Indeed, in all our industrial facilities, one key challenge is to increase operational efficiency. More and more, companies are asked to reduce their energy cost, while at the same time being more productive with a varying energy price.

Customers need to have an in-depth energy usage view to plan for better reductions:  Reduce the energy bills while still having the same production capacity.

Customers need to easily contextualize production with energy usage to improve operational efficiency:  Simplify and standardize the energy management process.

Minimize the carbon footprint of the plant:  Achieve CO2 reduction goals.

2.1.2.

Provide regulation compliance and deliver reports Customers need to regularly publish reports for compliance.

Whatever the segment, standards guide companies to implement an energy management solution:  Can I comply with ISO 50001 certification?

In the plant sources of data are different, needs and tools are multiple:  Suffering from multiple repositories of data.

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2 – Customer challenges 2.2.

What are the values of the solution?

The Plant Energy Performance solution provides key values to overcome the energy challenges.

2.2.1.

Solution to better master electrical energy consumption & reduce cost Gain valuable insight into your power network: Power Monitoring Expert interface gives insight into electrical system health and energy efficiency so you can take informed decisions to improve power system performance.

Optimize operational efficiency: 

Understand the cause of events affecting your electrical system, using advanced power forensics including smart alarm clustering and graphical events timeline.



Use trending and energy modeling to identify abnormal usage of electrical energy and other utilities (W.A.G.E.S.).



Avoid power factor and peak demand penalties.

Maximize operational lifecycle efficiency: 

Use energy benchmarking to reveal opportunities and baseline comparisons to validate savings.



Use shadow billing to identify errors in utility bills.



Analyze equipment performance to support proactive maintenance and extend lifespan.

2.2.2.

Solution to provide regulation compliance and deliver Report Simplify reporting and compliance:

2.3.



Align with energy efficiency and green building standards.



Track energy performance indicators (EnPI) as per ISO50006.



Verify utility/grid service and internal compliance to power quality.



Comply with common IT practices and align with cybersecurity best practices.

Glossary A glossary is available in the appendix of this document. Please refer to it whenever necessary.

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3 – Solution overview

3.

Solution overview

3.1.

Solution presentation The solution proposed in this guide is helping customers to optimize their plant energy consumption and benefit from tariffs variation to save costs and save up to 30% for intensive energy processes consumers at those facilities.

3.2.

Main functions Data Visualization

Data preparation

Data treatment

Process Data Acquisition

Power Data Acquisition

Page 19

Figure 2: Main functions of the Plant Energy Performance solution 

Collecting Energy data directly from the devices.



Collecting Energy data in combination with process information via the ePAC M580.



Making the link between devices, ePAC and Power Monitoring Expert via OFS and ETL tool.



The PME Software provides graphics, trends, alarms, reports and dashboard based on your KPIs.

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3 – Solution overview 3.2.1.

Data acquisition This main function retrieves data from the different sources supporting several communication protocols: Modbus TCP, Modbus RTU, ION or OPC DA. Retrieving data from our main product offer is eased thanks to pre-configured device types, including: 

Power and energy monitoring devices



Contactors and protection relays



Circuit breakers trip units



Smart panels



Power quality mitigation equipment

Additional process data can also be collected and then integrated into Power Monitoring Expert database through a dedicated interface (ETL) to store data from an Historian server or from a csv file.

3.2.2.

Data processing Specific tools allow you to manage data, convert and create custom KPIs to retrieve most adequate insights from your plant. Some additional modules can also be configured to help save engineering effort or gain more insights on the plant energy behavior such as: 

Billing Module: Energy-based billing and reporting, including consumption monitoring and reporting at the branch circuit level.



Breaker Module: Circuit breaker aging and breaker settings monitoring.



Capacity Management Module: Generator and Uninterruptible Power Supply (UPS) capacity monitoring and reporting. Includes transformer and UPS loss monitoring.



Energy Analysis Module: Energy consumption monitoring and modeling, including energy usage by process area or by product output.



Power Quality Performance Module: Analysis of power quality events and disturbances and their impact on the monitored system.

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3 – Solution overview 3.2.3.

Data Visualization With PME, we benefit from the most advanced energy visualization and analysis tools which calculate, model, forecast, track and place at your fingertip your main energy performance indicators.

It presents a reinvented alarm management with smart events and alarms that are clustered for intuitive and powerful filtering, searching and categorization of events and alarms. Graphical timeline analysis tools are easily configurable to analyze events and alarms sequence, location and potential impact.

Several tools are available for visualization, such as: 

Dashboards application to view high level historical and real-time data with multiple gadgets.

Figure 3: Power Monitoring Expert Dashboards

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3 – Solution overview 

Diagrams application to view historical and real-time data online and graphics diagrams.

You can view the network diagram and any tailored made diagrams.

Figure 4: Power Monitoring Expert Diagrams 

Trends application to view trends for real-time and historical data

Figure 5: Power Monitoring Expert Trends 

Alarms Viewer to see software generated and device-based Alarms in Power Monitoring Expert.

Figure 6: Power Monitoring Expert Alarms

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3 – Solution overview 

Reports application to generate data reports either based on a schedule or a trigger event.

Several formats are available when generating the report, to be shared within a private group or made available for all users. A large number of default report templates are already provided inside Power Monitoring Expert, which can be customized to quickly fit your expectations.

Figure 7: Power Monitoring Expert Reports

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3 – Solution overview 3.2.4.

Typical Applications Some key applications using our Plant Energy Performance solution are listed below: 

Continuous Thermal Monitoring to avoid electrical fires thanks to thermal monitoring devices installed on busbar, their data pushed into PME database.



Insulation Monitoring in OT and ICU to help prevent electrical shock, thanks to isolated smart panels, IM20-H and IFM-12H equipment communicating with the PME database.



Breaker Settings Monitoring to avoid disruption of business by helping to prevent ED failures using our best in class breakers and breaker and power analysis add-on modules to get the most of your electrical system.



Power Quality Monitoring to quickly and easily identify power quality issues, and manage their impact to keep them from disrupting or damaging critical loads and equipment.



Capacity Management to help prevent disruption from electrical overload.



Utility Bill Verification to verify the accuracy of the utility bill from both metering and bill calculation perspective.



Energy benchmarking to compare the efficiency of energy use across buildings/plants/process lines and gain understanding of what makes one facility less energy consuming than others.



Energy Usage Analysis to determine, understand and analyze what factors contribute more to energy usage, track KPIs and create models to compare actual against expected energy consumption.



Process data from ePAC M580 to make the link between power consumption and control command to better manage device energy consumption.



Energy Efficiency Compliance to respect national or international energy efficiency certifications bodies such as ISO 50001.



Greenhouse Gas Reporting to track and report carbon emissions for public disclosure/transparency of your company.

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4 – Solution Architecture

4.

Solution Architecture Description

4.1.

EcoStruxure Plant Architecture A typical EcoStruxure architecture for energy management solution is represented below with the three main layers: Connected Products, Edge Control and Apps, Analytics & Services.

Figure 8: Plant Energy Performance solution typical architecture

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4 – Solution Architecture 4.2.

Architecture Dataflow The following drawing shows the main dataflows used in the solution.

Figure 9: Data flow from different sources into Plant Energy Performance solution 

Direct flow from additional devices communicating on Modbus with PME to collect data.



Process flow to get live process values from the field trough the ePAC M580, and OFS.



Shared flow with System Platform and PME.



Historized flow from Historian to PME for reports and dashboards. Or external flow can be integrated by importing external files (.xls, .csv, …) or data base.

For most of these flows, ETL configuration tool is providing the link between data sources and the PME data base.

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4 – Solution Architecture 4.3.

Architecture Components Description The objective of this section is to provide more information on the key products part of this solution and to highlight their role in the solution processing.

Products are presented by reference to the three layers of an EcoStruxure Plant architecture.

4.3.1.

Connected Products Power devices as well as motor control devices and sensors can be used in this solution to gather process and power consumption data.

Sepam Sepam are protection relays specifically created for custom applications to help protect your power system, and are the product of Schneider Electric’s 20 years of experience in digital relays.

Figure 10: SEPAM Series 80 For detailed information about this product, please refer to : https://www.schneider-electric.com/en/product-range/935-easergy-sepam-series-80

Tesys T Tesys T motor management system are providing main motor protection and control functions. It incorporates a communication interface for remote supervision and control of the motor, trough multiple networks protocols.

Figure 11: TesysT For detailed information about this product, please refer to : https://www.se.com/uk/en/product-range-presentation/1508-tesys-t/#tabs-top

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4 – Solution Architecture Altivar Altivar process family includes variable speed drive with embedded services dedicated to process industry and utilities for a large range of motors from 0.75 kW to 1200 kW.

Figure 12: Altivar Process For detailed information about this product, please refer to : https://www.schneider-electric.com/en/product-range/62317-altivar-process-atv600/ Power meter There are many different ranges of power meters within the Schneider Electric portfolio.

Devices with Modbus RTU or Modbus TCP connectivity can easily be used in our solutions.

For instance, PowerLogic PM5000 series are compact, versatile power meters for energy cost and basic network management applications. They can perform a high-level assessment of the power quality in an electrical network.

Figure 13: PM5000 series For detailed information about this product, please refer to : https://www.schneider-electric.com/en/product-range/61281-powerlogic-pm5000-series/

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4 – Solution Architecture

Harmony Hub Wireless transmitters technology reduces the wiring and the cost of installation. Harmony Hub converts radio frequency inputs into various communication protocols and operates as intermediate equipment between a transmitter and a PLC or equipment such as industrial PCs that support Modbus TCP protocols.

A large range of Zigbee Sensors (Temperature & humidity sensors (TH110 & CL110), Push buttons, Limit switch, Energy meter, and so forth) can operate with the Harmony hub.

Figure 14: Harmony Hub For detailed information about this product, please refer to: https://www.schneider-electric.com/en/product/ZBRN1/harmony-hubwireless-to-modbus-tcpethernet-gateway/

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4 – Solution Architecture 4.3.2.

Edge control Modicon PAC Modicon M580 delivers enhanced capabilities for better performance and availability to help you maximize your total cost of ownership. Ready for the future, the Ethernet-based Modicon M580 offers connectivity capabilities to help you to share process data to the upper level in a cyber secure environment.

.

Figure 15: ePAC M580 For detailed information about this product, please refer to: https://www.schneider-electric.com/en/work/campaign/m580-epac/ System Platform System Platform is the world’s only responsive, scalable solution for supervisory, SCADA, HMI, and IIoT applications that integrates the process with the enterprise. System Platform provides a collaborative, standards-based foundation that unifies people, processes, and assets across all facilities for continuous operational improvement and real-time decision support.

Figure 16: System Platform SCADA overview

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4 – Solution Architecture 4.3.3.

Apps and Analytics EcoStruxure Power Monitoring Expert (PME) EcoStruxure Power Monitoring Expert provides power monitoring and management for one or several facilities. With this system, you can measure, manage, and improve your energy availability, reliability, and efficiency. It is a complete, interoperable, and scalable power management software solution that helps you to optimize your power distribution infrastructure, maximize operational efficiency, and improve your bottom-line performance.

Management Console The Management Console is used to add, remove or configure system components in an object model environment, such as metering devices, in the power management system of PME. The Management Console Tools menu provides access to device and system configuration, maintenance, and programming tools such as: 

Database Manager to perform maintenance tasks on the product's databases.



Designer to configure devices and add custom functionality to them.



Device Type Editor to create device drivers for Modbus and OPC devices, in Power Monitoring Expert, for which pre-configured drivers or downloadable add-on drivers do not exist.

Vista Vista is the Power Monitoring Expert component that displays and controls your power monitoring/management system.

Figure 17: Vista overview

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4 – Solution Architecture Web Applications

Figure 18: Dashboard webpage example The Web Application component includes the following applications for your power monitoring requirements: Dashboards: The Dashboards application provides a way to visualize present and past energy usage in meaningful graphic representations called gadgets. These gadgets display PME energy and process data taken from your underlying power monitoring system, which can be energy, process or KPI data, enabling you to make informed decisions about your operations that may impact present and future energy needs.

Diagrams: The Diagrams application allows users to access and display Vista diagrams in the Web Application interface. The Diagrams application manages the necessary data processing and system functions at the server and uses XML to process Vista objects and data for display on the web pages.

Tables: The Tables application allows you to quickly build an on-demand view of real-time data from devices configured in the Management Console component.

Trends: The Trends application allows you to monitor current system conditions by displaying real-time data in a graphical format. You can configure trend settings to include data from the database as it is logged (referred to as historical data), or you can combine real-time data and historical data in the trend diagram. In addition, you can save the trend data as a csv file.

Alarms (includes alarms and events): The Alarms application allows users to view system alarms and events in a tabular format. You can tailor the system view to your needs by choosing which alarm states, priorities, date range, and devices you want to view. You can also select the columns that you want to see, thus controlling the information you find helpful.

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4 – Solution Architecture Reports: The web-based Reports application allows you to select, configure, generate, and manage comprehensive reports based on historical data contained in your databases. The reports are designed for energy consumption and usage, power quality compliance and analysis, and generic system usage. The reports can be generated on a defined schedule and when system events and device alarms occur, and then distributed via email or sent to a file share or a printer.

ETL configuration tool ETL is a powerful data migration tool with support for many products and data stores. The ETL tasks perform the following functions: 

The Extract task reads data from a data source.



The Transform task converts the extracted data into a form that is compatible with the target data store.



The Load task writes the data to the target data store.

Figure 19: ETL Engine ETL Administration tool can transfer data from and to multiple sources:

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4 – Solution Architecture Historian The Historian is a high-capacity, high-throughput server that stores time-series data. The historian acquires and stores process data at full resolution or at a specified resolution and provides realtime and historical data together with configuration, event, summary, and associated production data to client applications on the desktop.

The historian combines the power and flexibility of Microsoft SQL Server with high speed acquisition and efficient data compression.

Figure 20: Historian overview The Historian is designed to: 

Handle the volume of time-series data.



Handle the rapid storage rate of time-series data.



Extend SQL to effectively handle time-series data

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5 – Solution use case example

5.

Solution use case example This solution example is tailored to wastewater treatment plants to: 

Improve efficiency of new and existing plants.



Decrease the energy consumption, the CO2 emission and the carbon footprint.

The final goal is to optimize water and wastewater plant energy consumption, reduce energy tariffs cost variation effects, and save up to 30% for intensive energy processes at those facilities.

The demo shows a mid/large-size wastewater treatment plant, the primary and secondary treatment are used in this example.

The selected use case architecture is described below.

Figure 21: Example of use case architecture

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5 – Solution use case example Use case architecture description: This use case targets an EcoStruxure Plant architecture to represent a medium to large sized modular automation system in a typical water and wastewater plant. In this architecture, the following pieces of equipment are installed: 

Standalone and redundant M580 ePAC.



A server with System Platform, Historian and OFS.



A server with Power Monitoring Expert components, ETL configurator tool and OFS.



An engineering station with EcoStruxure Control Expert to maintain the process application.



A set of field devices and power meters to collect energy data from pumps, air compressor and high energy consumers.

The process is described below.

The following industrial process of a pre-treatment process of a wastewater plant facility has been modelled as in this example. Focusing on actuators, it includes a Primary clarifier with an Inlet pump, a motor 1 to power the scraper. Two compressors provide air to the Aeration basin and the Secondary clarifier is design on the same model as the Primary clarifer. A pump is collecting sludges to the sludge treatment unit. Sensors and Instruments are out of this guide description.

Figure 22: Example process P&ID

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5 – Solution use case example Use case description: Power Monitoring Expert is used to collect energy consumption data, to prepare the main KPI, and to display the relevant information.

The following flows are used in this use case: Server 1 – SCADA Process

Server 2- New for energy management

PME

System Platform ETL

OPCClient

SQL OPCClient

Historian

OFS

OFS SQL Process

PLC 1

PLC 2

PM

PM

DRIVES

DRIVES

SENSORS

SENSORS

Historical data acquisition from Historian database Real time data acquisition from PLCs

Figure 23: Example flows illustration Two way of retrieving the data are used: 1.

Data from the Historian database is retrieved using the ETL tool. This tool retrieves the values in the historian data and stores them in the PME database.

2.

An OPC client device created in the PME Management Console uses OFS to retrieve realtime data from the M580 ePACs and stores them in the PME database.

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5 – Solution use case example This solution delivers key insights into the process such as: 

Visualization though dashboards of the custom KPIS, such as energy consumption or energy cost of each area for predefined periods of time (hour, day, week, month, year).

Figure 24: Example Power Monitoring Expert Dashboards 

Detailed analysis with trends on specific real time data to be able to take the appropriate actions for optimization.

Figure 25: Example Power Monitoring Expert trends

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5 – Solution use case example 

Custom detailed reports on water quality, energy consumption.

Figure 26: Example Power Monitoring Expert Report Use case of added value of M580 data to Power Monitoring Expert to optimize energy management.

In addition to pumps or air compressors energy data collected through ePAC M580 => OFS => ETL to PME, we collect and share device control commands and process status. From the trends we can easily identify periods of time when equipment’s are running without load. This information highlighted from a KPI is helping to optimize the process to reduce and help prevent such unnecessary usage and thereby increase plant energy efficiency.

Dashboards can easily display for a specific area or device the energy consumption during different periods (compare to yesterday / to last week, and so forth) to help to identify an energy consumption drift and determine the appropriate maintenance operation to identify to the root cause.

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6 – Appendix

6.

Appendix

6.1.

Glossary The following table describes the acronyms and defines the specific terms used in this document.

Term

Description Extract, Transform, and Load. A flexible interoperability tool that transfers

ETL

data from one data store to another. The ETL Engine executes ETL jobs that you create and configure.

KPI

Key Performance Indicator

OFS

Schneider Electric OPC Factory Server

OPC

Object Linking and Embedding (OLE) for Process Control OPC Data Access, a group of client-server standards that provides

OPC DA

specifications for communicating real-time data from data acquisition devices such as PLCs.

P&ID

Piping and Instrumentation Diagram

PAC

Programmable Application Controller

ePAC

Ethernet Programmable Application Controller

SCADA SP

WSP W.A.G.E.S EnPI

Supervisory Control And Data Acquisition system System Platform (Wonderware by Aveva), is the new official name of formerly called WSP Wonderware System Platform is an industrial software platform built on Wonderware’s ArchestrA technology Water, Air, Gas, Electricity and Steam Energy Performance Indicator

Table 1: glossary

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6 – Appendix 6.2.

Reference Documents The following table is a list of documents you might want to refer to when more details are needed.

Document Title

Reference

Power Monitoring Expert 9.0 system guide

7EN02-0411-00

Plant Energy Performance solution description

N.A.

TVDA How Can I Connect PlantStruxure to Power Monitoring Expert

N.A.

Table 2: Reference documents

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About Schneider Electric Schneider Electric is leading the Digital Transformation of Energy Management and Automation in Homes, Buildings, Data Centers, Infrastructure and Industries.

With global presence in over 100 countries, Schneider is the undisputable leader in Power Management – Medium Voltage, Low Voltage and Secure Power, and in Automation Systems. We provide integrated efficiency solutions, combining energy, automation and software.

In our global Ecosystem, we collaborate with the largest Partner, Integrator and Developer Community on our Open Platform to deliver real-time control and operational efficiency.

We believe that great people and partners make Schneider a great company and that our commitment to Innovation, Diversity and Sustainability ensures that Life Is On everywhere, for everyone and at every moment. www.schneider-electric.com

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Due to evolution of standards and equipment, characteristics indicated in texts and images in this document are binding only after confirmation by our departments.

Version 2.1 – 02 2020 ©2019 Schneider Electric. All Rights Reserved. Life Is On Schneider Electric is a trademark and the property of Schneider Electric SE, its subsidiaries and affiliated companies. All other trademarks are the property of their respective owners.