Remote Energy Monitoring Unit Design and Implementation
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The document describes the design and implementation of a remote energy monitoring unit. The unit was developed to enable (1) online and continuous monitoring of energy consumption in manufacturing facilities, (2) setting targets for energy savings, and (3) including energy optimization in control loops. It utilizes an E10 energy analyzer to accurately measure energy and power consumption. Test results showed the unit can provide detailed energy consumption data based on measurements. This allows monitoring of key performance indicators like operation-based and product-based energy usage.
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Remote Energy Monitoring Unit Design and Implementation
- 1. Remote Energy Monitoring Unit Design and Implementation Date: November, 2011 Conference: The 37th Annual Linked to: eSONIA (FP7 RDT Project) Conference of the IEEE Industrial Electronics Society Title of the paper: Remote Energy Monitoring Unit Design and Implementation Authors: Bin Zhang, Corina Popescu, Andrei Lobov, Jose L.Martinez Lastra Contact information Tampere University of Technology, FAST Laboratory, P.O. Box 600, If you would like to receive a reprint of FIN-33101 Tampere, the original paper, please contact us Finland Email: fast@tut.fi www.tut.fi/fast
- 2. 2 Remote Energy Monitoring Unit Design and Implementation Authors: Bin Zhang, Corina Popescu, Andrei Lobov, Jose L.Martinez Lastra Tampere University of Technology Factory Automations Systems and Technologies Lab. www.tut.fi/fast IECON 2011, Melbourne, Australia 8.11.2011 Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 3. 3 Outline 1. Introduction 2. Objective 3. Implementation • Hardware • E10 energy analyzer • Integration with Compressed Air Monitoring System • Interconnection with test bed 4. Results 5. KPIs Examples and Utililization 6. Conclusions and future work Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 4. 4 Introduction 1. Manufacturing contributes to approximately 1/3 of global energy consumption and CO2 emissions 2. Green house gas emissions should be reduced by 20% 3. Renewable energy utility and energy efficiency should be increased to 20% by 2020 4. Energy Prices fluctuate Solution: Introducing energy consumption as a parameter in the decision making process Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 5. 5 Introduction Conventional energy management methods: 1. Plant states are isolated 2. Energy consumption are not measured holistically and continuously Online energy measurement: 1. Online and continuous monitoring of energy consumption 2. Set targets for energy savings 3. Including energy optimization in control loop Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 6. 6 Objectives Past energy consumption monitoring relies on theoretical estimations for manufacturing a part Objectives 1. Online energy monitoring in real time 2. Accurate energy consumption 3. Accurate compressed air consumption 4. Monitoring in details 1. Total consumption 2. Operation based consumption 3. Product based consumption Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 7. 7 Implementation: Hardware 1. S1000 smart RTU embedded with E10 energy analyzer 2. AC/DC converter 3. Current transformers 4. 16-pin connector (to integrate with the controlled equipment) 5. Ethernet connector Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 8. 8 Implementation: E10 energy analyzer 1. Real time energy, power, current measurement 2. 3- phase 3. 8 inputs and 8 outputs 4. Device configuration, ST programming, HMI design and web service editing via web browser 5. HMIs hosted in the device and accessible through web browser Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 9. 9 Implementation: Integration with Compressed Air Monitoring System WS/ SOAP messages Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 10. 10 Implementation: Interconnection with test bed Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 11. 11 Result Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 12. 12 KPIs Examples and Utililization Online monitoring of energy-aware KPIs 1. Energy consumption per product • Used as one parameter in energy footprint in life cycle analysis (LCA) 2. Energy consumption per operation • Used for energy optimization o Monitor the energy consumption per operation o Evaluate contribution of each operation to final product o As valuable/indirectly valuable/ worthless o Eliminate worthless operation Monitored energy consumption published as web service events Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
- 13. 13 Conclusion and Future Work 1. The remote energy monitoring unit can provide detailed information on energy consumption based on measurement instead of estimation 2. Results can be monitored by operator through embedded HMIs 3. Results are published as events and can be integrated to any monitoring system supporting WS-Eventing 4. Energy-aware KPIs such as operation-based energy consumption and product-based energy consumption can be monitored using the remote energy monitoring unit 5. The solution allows integration with other units, e.g. Pressurised Air measurement. 6. A variety of monitoring applications can be designed for analyzing/monitoring KPIs and optimizing energy efficiency utilizing web services Remote Energy Monitoring Unit Design and Implementation / IECON 11/8/2011 2011
Notes de l'éditeur
- Nowadays, manufacturing industry contributes to approximately 1/ of global energy consumption and CO2 emissions.European Council’s energy and climate change objective is to reduce greenhouse gas emissions by 20%, to increase share of renewable energy to 20% and make a 20% improvement in energy efficiency by 2020.Prices of energy fluctuate because of fierce competition and scarcity of energy resources.One possible solution is to introduce energy consumption as a parameter in the decision making process
- In conventional energy management methods, plant states are isolated and the energy consumption are not measured holistically and continuously. These limitations prevent energy efficient decision making.Significant energy efficient improvement can be achieved by online energy measurement. In this kind of measurement, energy consumption is monitored on-site and continuously. Targets for energy saving can be set. Monitor energy online and contineously. Energy efficiency can be optimized significantly by including energy optimization in the control loops.
- Past energy monitoring relies on theoretical estimation for manufacturing a part lacking accuracy. The objective of this paper is to design the remote energy monitoring unit for real time energy monitoring to achieve accurate energy consumption and compressed air consumption monitoring. The monitoring of energy consumption is in much details including total energy consumption, operation based energy consumption and product based consumption
- The remote energy monitoring consists of an E10 energy analyzer embedded on a S1000 smart RTU, AC/DC converter, 3 current transformers, a 16-pin connector, an Ethernet connector and 3 sockets. The 16-pin connector is used for connecting with I/O Points in the monitored manufacturing systems. The use of Ethernet enables to monitor online and publish energy consumption as events in a web service. Sockets are the power supply for the manufacturing devices.
- The E10 energy analyzer is able to provide real time energy, power, current measurement in 3 phases. It has 8 inputs and 8 outputs. The device configuration, ST programming, HMI design and web service editing can be done easily with web browsers, no software needs to be installed. It also provides online monitoring.
- The information such as flow rate and pressure is obtained from the Compressed air monitoring system. In CAMS, there is also a S1000 RTU with web service publishing events. The message exchange of the two devices are achieved with SOAP messages. With flow rate and pressure, it is possible to calculate pneumatic energy consumption.
- The interconnection between the REMU and the FESTO MPS is done with the 16-pin connection cable. Interconnections with the Testing station is shown in the table. The testing station has 4 operations- switch on the air slide, advance or retract the ejecting cylinder, raising the lifting cylinder and lowering the lifting cylinder. The changing from false to true indicates the start of the operation, while changing from true to false indicates the end of the operation. In this way, operation based energy consumption can be measured. Similarly, the light barrier to the previous station is used to indicate the period of producing a part.
- The testing with the FESTO production line is shown on the HMI page which is accessed via browser. It shows general data (power, voltage, current, pressure and flow rate) on the left with the gauges. In the middle, two meters show the total energy consumption (electrical and pneumatic), below, product based energy consumption is shown (electrical in blue and pneumatic in purple), on the right side, the energy consumption of each operation is displayed.
- The energy monitoring unit can be used to monitor two energy- aware KPIs (energy intensity), energy consumption per product and energy consumption per operation. The first one can be used as one parameter in energy footprint in life cycle analysis (LCA), while the second one can be used in energy optimization. The energy optimization can be achieved in 3 steps. 1. monitor energy consumption per process, 2. evaluate the usefulness of the operation contributing to final product and scale as valuable, indirectly valuable and worthless. 3. eliminate worthless operation if the percentage of the worthless energy consumption is high.The energy consumption information is published as events in web service.