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BSI PD IEC/TR 62837:2013

$215.11

Energy efficiency through automation systems

Published By Publication Date Number of Pages
BSI 2013 78
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This Technical Report provides to the technical committees a framework for the development and adaptation of documents in order to improve energy efficiency in manufacturing, process control and industrial facility management.

PDF Catalog

PDF Pages PDF Title
4 CONTENTS
8 FOREWORD
10 INTRODUCTION
11 1 Scope
2 Normative references
3 Terms and definitions
3.1 Energy
12 3.2 Energy use and energy consumption
13 3.3 Energy efficiency
15 3.4 Energy performance
3.5 Energy management
3.6 Automation process equipment
16 3.7 Automation system
17 4 Abbreviations and alphabetical index
4.1 Abbreviated terms
18 4.2 Alphabetical index of terms
20 5 Generic models
5.1 Functional hierarchy of production systems
Figures
Figure 1 – Functional hierarchy of production systems according to IEC 62264
21 5.2 Functions in level 4
5.3 Functions in level 3 or lower
Figure 2 – Energy functions mapped over the functional hierarchy levels (IEC 62264)
22 5.4 Application function and automation function
23 Figure 3 – Structural overview of automated industrial plants
24 6 Generic tools and methods
6.1 Organisational issues
6.2 Energy managed unit (EMU)
Figure 4 – Plant application with automation assets
25 6.3 General recommendations
6.3.1 Architecture of energy sourcing
Figure 5 – Energy managed unit (EMU)
26 6.3.2 Managed energy efficiency
27 6.3.3 Low power states
6.3.4 Standardised component interface
6.3.5 Control systems
28 6.3.6 Classification and energy labels for components and systems
6.3.7 Simulation of systems and components
29 6.4 Key performance indicators (KPIs) for energy efficiency
6.4.1 Basics for defining KPIs for energy efficiency
Figure 6 – Start up phase of a system and its power consumption
30 Figure 7 – Creation of an energy baseline model
Figure 8 – Measurement of energy savings
31 Tables
Table 1 – Guideline for EMU energy data
32 6.4.2 Recommendations for defining KPIs for energy efficiency
Figure 9 – KPI and its driving factor
33 6.4.3 Guidelines for defining KPIs
35 Figure 10 – Characteristics of the energy baseline model
36 Figure 11 – Production system hierarchy
37 Figure 12 – Energy consumption characteristics of equipment
38 Table 2 – Guideline to define KPIs for EMU
39 Table 3 – Guideline for the definition of KPIs for products
40 7 Applications
7.1 The application point of view
7.1.1 Energy consumption in industry
Table 4 – KPI description based on ISO 22400-2 model
42 7.1.2 Characteristics of production processes
7.2 Discrete manufacturing
7.2.1 Description
Table 5 – Characteristics of production processes
43 Figure 13 – Model of automotive production
44 7.2.2 Recommendations for discrete manufacturing
45 7.3 Process industry
7.3.1 Description
Figure 14 – Supervisory control
46 7.3.2 General recommendations for the process industry
47 7.3.3 Existing standards
7.3.4 Gaps
7.3.5 Specific recommendations
48 7.4 Support functions
7.4.1 General
7.4.2 Building automation and facility management
8 Components
8.1 The component specific view
49 8.2 Actuators
8.2.1 Electrical drives: regulate or self-learn optimal energy efficiency
8.2.2 Electrical drives: standardised intermediate current link
50 Annex A (informative) System boundary
Figure A.1 – Unit process model
51 Figure A.2 – Unit process model dealing with the direct and indirect influences
Figure A.3 – Process units in the definition and context of plants
52 Figure A.4 – Typical expanded equipment hierarchy
53 Annex B (informative) Current approaches for KPIs for energy efficiency
B.1 Existing KPIs
B.2 KPIs for components
B.3 KPIs for products
54 B.4 KPIs for systems
B.5 Target values of KPI by industry sectors in Japan
55 Table B.1 – Target values of KPI by industry sectors in Japan
56 B.6 How to measure the energy consumed to produce a product
57 Figure B.1 – Product production process
Figure B.2 – Production process flow
58 Annex C (informative) Energy baseline model
C.1 Guidelines for the creation and usage of an energy baseline model
Figure C.1 – Energy baseline model
59 C.2 Examples of a facility energy baseline model
C.2.1 General
C.2.2 Cooling water pump with parallel pumping control
Table C.1 – Guidelines for defining an energy baseline model
60 C.2.3 Cooling water pumps with variable frequency AC drive
Figure C.2 – Cooling water pump facility with parallel pumping control
61 Figure C.3 – Cooling water pumps with variable frequency AC drive
62 Annex D (informative) Energy labels
D.1 Examples of energy labels
D.2 Energy label for electrical motors
Figure D.1 – Examples of energy labels
63 Annex E (informative) “RENKEI” control
E.1 Background of “RENKEI” control
E.2 “RENKEI” control
64 Figure E.1 – “RENKEI” control
Figure E.2 – “RENKEI” control detail
65 Figure E.3 – Energy flow in a factory
66 Annex F (informative) Measurement and control technologies that support energy efficiency improvement
F.1 Technologies to improve energy efficiency
F.2 Detection of air leakage
Figure F.1 – Components and automation functions
67 F.3 Control valves
Figure F.2 – Pipe air leaks
Table F.1 – Pipe air leaks detected by ultrasonic sensing device
68 F.4 Control loop performance improvements
Figure F.3 – Structure of control valve
Figure F.4 – Control loop performance improvements
69 F.5 Combustion control
Figure F.5 – The effects of control performance analysis and tuning
Figure F.6 – Relationship between air-fuel ratio and heat efficiency (combustion)
70 F.6 Advanced process control (APC)
Figure F.7 – CO and O2 control system for combustion furnace
71 Figure F.8 – APC
72 F.7 Air supply pressure control
F.8 Steam header pressure control
Figure F.9 – Example of APC application for distillation column
Figure F.10 – Air supply pressure control by pressure transmitter and compressor
73 F.9 Optimal operational planning system
Figure F.11 – Control of steam header pressureby means of compressor quantity control
74 F.10 Analytical sensors
Figure F.12 – Optimal operational planning system
75 Figure F.13 – Coal gasification plant
76 Bibliography
BSI PD IEC/TR 62837:2013
$215.11