A TechnicalApproach to
Optimization ofEnergy Usage(OEU™)
www.odva.org

Presenters
Cliff Whitehead
Manager, Business Development
Rockwell Automation
cjwhiteheadjr@ra.rockwell.com

Mike Crowley
Offer Manager
Schneider Electricmichael.crowley@schneider-electric.com

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Mock Energy Debate

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Before examining a "day in the life of energy", in the spirit of thepolitical season, it might be interesting to hold a MOCK debate
about energy. Our presenters stepped out of their roles andportrayed two fictitious opponents debating the relative merits of
their energy plans. Here is the transcript!
Speaker #1
We all know that the energy issue has become a top priority worldwide for individuals,
companies and governments. World energy prices have soared in the past decade andfears of an environmental disaster have brought how we develop and use energy to theforefront. There is a lot of debate about which energy sources are best, the most costeffective and the least harmful to the environment. There can be no doubt however, thatthe greenest type of energy initiative is energy efficiency. The energy not used is energythat did not have to be mined or drilled or delivered to the generating station. It is 100%
green and has zero negative impact on the ecosystem.
That is why I have developed a three step program for energy efficiency. My program will
focus on Industrial Energy, which contributes more than a third of all carbon emissions
worldwide. My three step program (called Energy MOM) uses measurement,
optimization and maintenance to reduce and sustain significant energy reductions.
Energy MOM has been implemented successfully in industrial facilities with rapid returnof investment. My plan is proven, effective and improves the competitive position ofcompanies that use it.

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

page 5www.odva.org

Before examining a "day in the life of energy", in the spirit of thepolitical season, it might be interesting to hold a MOCK debate
about energy. Our presenters stepped out of their roles andportrayed two fictitious opponents debating the relative merits of
their energy plans. Here is the transcript!
Speaker #2
I would also like to thank Stone Mountain resort and all of you who have come out today
to listen. The challenges facing the country and planet today are significant and require athoughtful approach. I have had a deep interest in energy issues and especially energy
efficiency for many years. As a youngster, I was taught to respect the planet, to use no
more than I needed and to give back to the ecosystem. That is why I have devised anenergy plan that provides big savings to companies that want and need to conserve. We
know that energy prices continue to climb - and this increase has hit our industrial sector
very hard. To stay competitive, companies need a disciplined approach to energy
savings.
My program uses a unique process I call Energy POP, which stands for plan, operate
and perform. The Energy POP program uses methods that rely not only on provenenergy management techniques, but also in the innovative spirit of businesses to takecharge of their energy bill. Energy POP frees up capital so that companies can reinvest
money in their operations and become market leaders. My plan encourages companies
to take responsibility for their own energy consumption.

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

page 6www.odva.org

Before examining a "day in the life of energy", in the spirit of thepolitical season, it might be interesting to hold a MOCK debate
about energy. Our presenters stepped out of their roles andportrayed two fictitious opponents debating the relative merits of
their energy plans. Here is the transcript!
Moderator: Speaker #1, can you describe how your plan differs from your opponent?
Speaker #1
My plan is unique in its approach, because it incentivizes businesses to invest in thetechnologies that can reduce consumption and emissions. It creates a partnership
between groups to help finance improvements. Energy MOM creates a safe haven, sothat companies know that if they invest with Energy MOM, they are protected fromadverse risk.
My opponent’s program does not provide these guarantees; in fact several companies
that tried his methods have since gone out of business. I don't think that his program's
record of success is one to be proud of. As a matter of fact, my opponent has stated that
47% of industrial facilities don't care about saving energy, they only want energy rebates.

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

page 7www.odva.org

Before examining a "day in the life of energy", in the spirit of thepolitical season, it might be interesting to hold a MOCK debate
about energy. Our presenters stepped out of their roles andportrayed two fictitious opponents debating the relative merits of
their energy plans. Here is the transcript!
Speaker #2
That is not true. You may be entitled to your own luxury rental car, but not to your own facts!
Those companies you say went out of business actually became more profitable becauseof the energy savings that Energy POP provided. They became more attractive and wereacquired by other companies in part due to low operational costs. In fact independentstudies have shown that Energy POP is 27% more effective in reducing operational costs at
manufacturing facilities than Energy MOM. Not only better, but POP also provides faster
results because companies are highly motivated to achieve results.
Look, I want ALL industrial facilities to benefit from energy efficiency. Like the plant
manager I met from Dubuque, Iowa, who told me that if only he could save 10% on his
energy bill, he could invest in new equipment to make his production line more competitive.

Moderator: Speaker #2, can you describe in one paragraph the philosophical differences between
you and your opponent's energy plan?
Speaker #2
My plan relies on the Plan, Operate and Perform methodology. My program also allows
companies to reinvest the savings they earn. So all cuts in energy stimulate even more cutsin energy. My opponent’s program relies on guarantees, which doesn't stimulate the same
performance from individuals and companies.

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

page 8www.odva.org

Before examining a "day in the life of energy", in the spirit of thepolitical season, it might be interesting to hold a MOCK debate
about energy. Our presenters stepped out of their roles andportrayed two fictitious opponents debating the relative merits of
their energy plans. Here is the transcript!
Moderator: Speaker #1, critics say that Energy MOM is actually very similar to Energy POP and thatlack of bipartisan dialog is actually holding back energy savings. How do you respond?

Speaker #1
Well, there are some similarities in the approach of both programs. Where my program
relies on Measure, Optimize and Maintain, my opponent relies on Plan, Operate andPerform. With some work, it might be possible to reconcile the gaps in my opponent’s
approach to create a unified plan.

Speaker #2
And I think there might be some room to work with my opponent to improve his methods
and create an approach that leverages the best ideas so that Industrial Energy consumers
can maximize their savings. If we could work together, we could create a standard method
for energy efficiency that reduces costs and create benefits for even more companies.

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

page 9www.odva.org

Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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OEU’s 3 Pronged Approach
Optimization of Energy Usage (OEU™)

Awareness of energy usage
Consuming energy more efficiently
Procuring energy at the lowest cost

Working Hypothesis• Energy is essential to produce products but has been an invisibleline item on production bills of materials and consequently anunmanaged resource (energy should be a managed resource in the
production domain).
• Increasing the availability of energy information and visibility ofenergy consumption will promote awareness by industrial
consumers of the need to manage energy as a production resource
which, in turn, will lead to best practices in OEU.
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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ODVA Energy SIG Objectives
Specification enhancement phases:
1. Awareness: Standard access to energy information
2. (a) Power Management: Commanding equipment toconservation states(b) Energy Management: Controlling energy demand
3. Standardized interface to the Smart Grid
Phase 1 was published in November, 2011
Included in CIP Networks Library, Volume 1, Edition 3.11

Phase 2a was published in April, 2012
Included in CIP Networks Library, Volume 1 & 2, Edition 3.12

Phase 2b work is in process, targeted for Fall 2013
publication
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Energy Consumption 101
Energy (W) is a resource that enables
work to be doneUnits of measure: Joules, kilowatt-hours, British
thermal units, etc.
Prefix kilo (x1000), mega (x106), giga (x109),
etc.

Power (P) is the rate of converting
energy to work per unit of timeUnits of measure: Joules per second, Btu perhour, kilowatts

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Electrical energy is a bit weird
Time is part of the energy unit:
kilowatt-hourAll other units put time in the power unit: J/s

How to visualize energy and power
Figure 1: Energy Odometer and Power Illustration

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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The mfg. energy opportunity

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Energy Flows in Manufacturing

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Power Distribution

Department Loads

Machine Mains

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Base Energy Object
Energy SupervisorCapabilities
Accuracy
Paths

Base Energy
object(0 .. 1)

• To Subordinate Objects• To Aggregated Objects
Reports energy and/or
powerStandardized reporting
units (kWh/kW)

Electrical energy
objectAssociatedBase Energy
Object Path
Non-electricalenergy object• 1 kWh = 3600 Joules
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Energy Reporting Methods
Odometer: Energy expressed as a 5-integerarray

Widely used, combines precision with wide rangeThree energy buckets• Consumed, generated, total• Values eventually roll over to zero and start overPower: expressed as a REAL (floating point)
value



Positive = energy consumed
Negative = energy generated

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Energy Capabilities Examples
Energy measured

Energy derived

EnergySourceInfeedVFD
monitorPower

Line ordepartment

Heating
element

Motor amps
(measured)

Overload relay

Voltage(assumed)

Energy proxy
Energy aggregatedSoftwareapplication

Energy fixed

MachineController orcontroller
to lineTranslator
controller

Generic
Non-CIPdevice
servo

Parent/child relationshipSpecified using EPATHs
Power supplyPower
supply300W
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Modbus Integration
Modbus energy information
Translator maps to Energy Object
Recommendations to place energy /power info in specified registersEnergy/power info contained in proprietary files(FC 20, 21) problematic to map to Energy Object

Modbus Integration SIG currently
working on mapping methods

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Break duration:
30 minutes
Start

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Phase 2aPower Management
Management activities to save energy
include:

Directing devices to go to known low power consumption pause
states during idle periods.
Directing devices to go into sleep states• Where even the device’s communications hardware is sent to its lowest possibleenergy consumption state for extended periods of time

The specification defines:The Power Management Object• Controls entry into and exit from energy saving pause states

EtherNet/IP specific sleep mechanism• Controls entry into and exit from sleep states

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Power Management Object
StatesPower OffPowerUp
UpdateStatus,CommonServices

Not Owned

Power
Down

Power
Down

Set Pass
Code
Clear Pass
Code

Owned

Request
Pause
Power Down
UpdateStatus,CommonServices

PausedWakefrom
Sleep1
Power Down

ResumeUpdateStatus,CommonServices
Complete
Pause (Internal
to Device)

Resuming

UpdateStatus,CommonServices

Request
Sleep

Sleep

1 Adaptation-specific Wake from Deep Sleep mechanism (example:
Ethernet Magic Packet)
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Timing Relationships
The Power Management object includes a number of time elements.
•

Requested Pause or Sleep Time – the time requested by a client issuing a Pause or•

Resume Time – the time required for a server to transition from the Paused state,•

Wake from Sleep Time – the time required for a server that supports the Sleeping state•

Minimum Pause or Sleep Time – the time required for a server to enter into and exit

Sleep; indicated the time until the server may be expected to have returned to a fully
operational condition.

through the Resuming state into the Owned state.

to transition from the Sleeping state to the Paused state.

from an energy saving mode. This time includes the Wake from Sleep Time and Resume
Time, as applicable, in addition to a time required to attain the agreed power usage level.

Requested Pause or Sleep Time
Resume Time
Wake from Sleep TimeTime to achieve low power level

Minimum Pause or Sleep Time
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Power (Watts)
100.00%100.00%80.00%

60.34%

Operating

60.00%

Pause
Sleep

40.00%
20.00%

14.71%

0.00%

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Phase 2b – Energy Management
Controlling Energy Demand

Demand

Average rate of energy consumed per interval of time, in kilowatts
EnergyPower
DemandDemand charges

Based on the highest interval demand in a month• $10 - $20 or more per kW• Depends on time of use (on-peak, off-peak)Demand is figured at the main utility meter
Demand acknowledges equipment capability to absorb short-timeoverloads

Demand managementDynamically controlling loads to reduce energy demand

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A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Phase 3
Smart Grid
Development of a standardized interface

ODVA does not anticipate direct connection ofdevices to the Smart Grid
Collaborating with other SDOs
• ASHRAE/NEMA Facility Smart Grid Information Model

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Agendao Optimization of Energy Usage (OEU™)o Energy SIG Goals and Objectiveso Energy Consumption 101
o Phase 1 – Energy Awarenesso Phase 2a – Power Managemento Ongoing and Future Activities
o Summary

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Energy Can Be a
Managed Resource
A “day in the life” of a manufacturing process shows how
OEU and the ODVA energy technologies can be applied tobalance risk, cost, and opportunity:•Risk: no need to alter the operating process to getenergy savings; can leverage installed base of CIP- and
MODBUS-enabled devices by executing commands andcollecting data over the existing communication cable;
reduced dependence on customization and proprietary
solutions•Cost: lower implementation cost through elimination ofcustom code, fewer meters, etc.
•Opportunity: Lower cost of implementation meansincreased granularity of information, leading to moresavings opportunities.
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Benefits
To the End User and OEMMore detailed energy info at very low cost
Reduced integration costs
Reduced operating costs through the applicationof this technology in automation and information
processes

To the Vendor and OEM

Integration of devices into the energy
management functionality of automation systems
Natural extension of CIP capabilities into a new
and differentiable market space

A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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Where is the Market Today?
• Much of the low fruit has been harvested
without much intervention from automation• Europe and Japan are ahead of the rest of
the world in adopting these practices• Global companies are starting to get themessage and create top-down strategies,
initially to create corporate good will
• Energy is slowly starting to become part of
the total cost of ownership…and it won’t belong before planning starting including
energy on the manufacturing BOM

What are you seeing?
A Technical Approach to Optimization of Energy Usage© 2012 ODVA, Inc. All rights reserved.

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For more information
To learn more about ODVA’s energy
initiative, visit www.odva.org and click
on Optimization of Energy Usage
To get involved in the ODVA Energy
activities, contact ODVA at:
Name: Adrienne Meyer
Phone: +1.734.975.8840 x2224
E-mail: ameyer@odva.org

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