Xu Shuang
Ankerui Electric Co., Ltd., Shanghai Jiading 201801
I. Analysis of power consumption characteristics of users in the industry
The metal products industry industry can be subdivided into metal structure manufacturing industries (including metal structures for manufacturing buildings, components, metal bridge structures, iron towers, iron frames, metal pillars, sluices, etc.), cast iron pipe manufacturing, chemical industry, and wood. , non-metallic processing equipment manufacturing, tool manufacturing: (1 cutting tool manufacturing (heavy): including drills, reamers, gear cutters, thread cutting tools, turning tools, saw blades and other metal cutting tools. Measuring instrument Production is not included in this category, included in the measuring instrument manufacturing industry; 2 mold manufacturing: including the manufacture of various metal molds; 3 hand tools manufacturing (light): including the manufacture of various wrenches, pliers, hammers, knives, Screwdriver, saw blade and iron, wood, bricklaying tools, etc.
The classification of the industry is very fine. It is a relatively small scale compared to the smelting and rolling industry and the electricity load is generally not very large (except in a few exceptions). Metals are used as raw materials to complete finished products through processes such as smelting, forging, rolling and stamping. It is very similar to the smelting and rolling industry, and the production nature is generally three-shift continuous operation.
Metal Products Industry User Equipment Category
category
Major equipment
Note
Non-productive load
Office lighting, office appliances, split and central air conditioning, living electricity (canteen rice cookers, electric water heaters, etc.), factory lighting and lighting
general
Auxiliary production load
Transmission hydraulic pump, conveyor belt motor, driving, workshop ventilation axial fan, welding machine
general
The main productive load
High and medium frequency heating furnaces, cutting machines, extruders, punching machines, welding machines
important
Safeguarding load
Electrothermal furnace circulating cooling water pump, furnace supporting lift hydraulic pump, air compressor, workshop equipment lighting, fire fighting and public security equipment
important
II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability
1. The industry has a large electricity load and is a continuous load that is not affected by time, season, and climate. It does not require full shutdown maintenance throughout the year. Therefore, there are loads that can be limited during the rest of the year.
2. Emergency peak load shifting is more difficult for the industry due to the fact that the whole production process is dominated by the entire assembly line, and the main power consumption equipment in the middle is high and medium frequency heating furnace (70% of the total load) and the response time is longer. Two hours.
3. When the user of the industry phase shifts in phases, the production line can be stopped in accordance with the requirements to stop part of the production line or stop one or more or even all of them.
Third, the industry users involved in the peak load limitation technology program
(I) Gap Level IV Participation Plan
1. Staged peak shift:
Under the premise of executing the peak-shifting instructions and completing the peak-discriminating index, while retaining the production line at the same time, combined with its own production process, it is possible to selectively put in different peaks of auxiliary production equipment at different times. Due to the forward-looking nature of the phase-shifted peak shifting, preparations can be started in advance, and the equipment with long service response time can be adjusted at different production intervals. Such as: increase the use of auxiliary equipment during non-peak hours, and reduce the use of auxiliary equipment to achieve 10% to reduce the burden at each peak period. At the same time, reducing the use of non-productive equipment such as office appliances plays an auxiliary role in energy conservation.
2. Emergency peak shift
Immediately after receiving the peak-to-peak instruction, all auxiliary equipment that can be stopped can be quickly deactivated, such as: intermittent use of equipment such as driving and welding machines, and at the same time, energy-saving assistance for non-productive equipment can be reduced.
(II) Gap Level III Participation Plan
1. Staged peak shift:
As the level of peak shifting is increased (ie, the peak shifting factor is increased), the decommissioning pipeline can be arranged on the basis of the IV stage phase shifting scheme. If there are 2 or more lines, one or more lines can be deactivated to achieve a reduction of 10 to 10 15% effect.
2. Emergency peak shift:
After receiving the peak-to-peak instructions, it followed the IV-level emergency peak-change scheme and adopted the phase-III phase-shifting scheme to phase out the pipeline.
(III) Level II Participation Scheme for Gap
1. Staged peak shift:
With the further improvement of the peak shifting grade, it is necessary to arrange the decommissioning of high and medium frequency heating furnaces for its main power-consuming equipment.
2. Emergency peak shift:
After receiving the peak-to-peak instructions, it followed the IV-level emergency offset scheme, and adopted the phase III phase-shifting scheme, and increased the number of decommissioning lines.
(IV) Gap Level I Participation Plan
1. Staged peak shift:
Since the load gap has reached the highest level, companies need to do their best to support the peak shift.
1) Arrange for a complete shutdown, annual maintenance of the equipment, or adjustment of rest periods on rest days.
2) If there are practical difficulties in the above plan or still need to participate in the peak shift after implementing the above plan, you can continue to adopt the phase-II, III, and IV phase-shifting schemes and methods as much as possible to invest in the maximum controllable load to meet more than 20% peak shift. need.
2. Emergency peak shift:
In case of non-discontinuity, after receiving the peak shift instruction, the IV grade emergency peak shifting scheme will be followed, and then the pipeline will be deactivated according to the peak shift requirement.
Fourth, the industry users involved in the peak load shifting risk and precautions
The industry is a high-risk industry and care must be taken to prevent the following accidents:
1. Loss of power will invalidate the circulating cooling system, support, and rotation system of high and intermediate frequency furnaces, etc. Failure to cool will damage the furnace body; failure to lift the tilt to turn the charge off will result in consolidation of the charge in the furnace Furnace damage, which will directly affect the recovery cycle, resulting in major losses;
2. Loss of power will cause direct damage to the production line, such as computer components, linkage devices, etc.; serious loss of the entire assembly line will result in significant losses.
3. Subsequent production equipment such as cutting machines, extruders, punch presses, etc., shall also be jammed due to loss of power, damaged by varying degrees of damage, materials and products being scrapped and even causing personal injury.
Therefore, it is not appropriate for users in the industry to participate in peak shifts to adopt mandatory power draws or remote control devices to control power cuts. Enterprises should formulate effective emergency plans, take the initiative to cooperate with the wrong peaks, eliminate the occurrence of malignant accidents, and shoulder the burden of social responsibility while minimizing losses.
V. Functions and Applications of Intelligent Power Monitoring
Power distribution system of a certain metal product factory in Suzhou, 10/0.4kV power distribution system for power monitoring and power management; monitoring range of T1, T2 transformer inlet cabinets, contact cabinets, temperature controllers for new substations , High-side instrument and comprehensive protection for remote real-time monitoring and power management. The system has a total of 31 instruments (including 26 smart electrical measuring instruments ACR220EL, 3 medium voltage protection devices AM5, 2 temperature control devices WHD), divided into 3 busses, which are pulled directly through the shielded twisted pair cable To the duty room is connected to the host expansion card to achieve data connectivity between the meter and the monitoring host on the bus.
5.1 Network Structure Topology
The monitoring system adopts a hierarchical distributed structure, namely station control layer, communication layer and bay layer; as shown in Figure (1):
Interval equipment layer mainly includes: multi-function network power meter, switch quantity, analog acquisition module and intelligent circuit breaker. These devices are corresponding to the corresponding primary equipment installed in the electrical cabinet, these devices are used RS485 communication interface, through the scene MODBUS bus networking communications, data acquisition on the spot.
The main network communication layer is: a communication server, its main function is to collect and collect in the field collection device, and at the same time
Station control management: equipped with high-performance industrial computers, monitors, UPS power supplies, printers, alarm buzzer and other equipment. The monitoring system is installed on the computer to collect and display the operating status of the field equipment and display it to the user in the form of human-computer interaction.
The above network instruments all adopt RS485 interface and MODBUS-RTU communication protocol. RS485 adopts shielded wire transmission. Generally, two wires are used for connection. The connection is simple and convenient. The communication interface is half-duplex communication, that is, both parties can receive and send data. Only data can be sent or received at the same time. The maximum data transmission rate is 10Mbps. The RS485 interface is a combination of balanced drivers and differential receivers. It has enhanced noise immunity and allows up to 32 devices to be connected on the bus. The maximum transmission distance is 1.2 km.
5.2 System Functions
5.2.1 System main interface
The main monitoring screen of the system mainly monitors the running status of the high-pressure loop in real time. Red represents the closing, and green represents the opening. When the breaker is dislocated, an alarm signal will be issued to remind the user to deal with the fault in time. This project adopts AM5 protector in the high voltage section of 10KV. The software interface displays the operating status of the comprehensive protection in real time and displays the measurement parameters of the comprehensive protection in real time.
Figure (2) High-pressure system diagram
Low-voltage power distribution secondary diagram, functional power telemetry mainly monitors the electrical parameters of the operating equipment, including: line three-phase voltage, current, power, power factor, electrical energy, frequency and other electrical parameters and the three-phase current of the outgoing circuit; The letter function realizes the display of the running status of the field device, mainly including: the switching and closing operation state of the switch and the communication failure alarm; when the circuit breaker is dislocated, an alarm signal is issued to remind the user to deal with the fault in time.
Figure (3) Secondary diagram of low voltage distribution
5.2.2 Parameter reading
The parameter reading function mainly completes the query of the electrical parameters of the low-voltage outlet circuits. Supports electrical parameter query at any time, with functions such as data export and report printing. The report queries the electrical parameters of the low-voltage loops of the two transformer substations of the substation, and mainly includes: three-phase current, active power, and active power. The names of the loops in this report are associated with the database to facilitate the user to modify the loop name.
Figure (4) Parameter reading
5.2.3 Report Statistics
The electricity consumption report function can select the time period to inquire, supports the accumulated electricity inquiry at any time, and has the functions of data export and report printing. Provide accurate and reliable power report for duty personnel. The names of the loops in this report are associated with the database to facilitate the user to modify the loop name.
Figure (5) Energy Report
5.2.4 Fault alarm
The schematic diagram of the system communication structure mainly shows the networking structure of the system. The system adopts a hierarchical distributed structure and simultaneously monitors the communication status of the equipment at the bay level. Red indicates normal communication and green indicates communication failure.
Figure (6) System Communication Structure
5.2.5 Load Trend Curve
The load trend curve interface allows you to visually check the load operation of the loop. View real-time and historical trend curves, click the corresponding button or menu item to complete the switching of corresponding functions; help the user to enter the trend analysis and fault recall, with curve printing function. Provides intuitive and convenient software support for analyzing the health of the entire system.
Graph (7) Trend Graph
Sixth, the main monitoring products
(1) ACR220EL meter for high voltage circuit or low voltage circuit
The main functions of the table are: LCD display, all-electric parameter measurement (U, I, P, Q, PF, F); four-quadrant energy metering, multi-rate energy statistics, maximum demand statistics; 4DI+2DO; RS485 communication interface , Modbus protocol. Dimensions: 96 x 96mm, opening size: 88 x 88mm. Suitable for low-voltage connection cabinets and outlet cabinets.
(3) Low voltage outlet cabinet selection ARD series
The meter measures protection functions such as three-phase current, fixed value query, fixed value setting, overload, phase failure (unbalance), locked rotor, underload, external fault, blocking, undervoltage, 8DI+4DO, power management, and leakage protection , SOE records, a variety of start mode, RS485 communication interface, MODbus protocol / Profibus-DP protocol optional.
(4) Energy-saving product optional rail table or APF active filter device
Lighting box DDSF1352 meter main functions: current specification 1.5 (6) A, 5 (20) A, 10 (40) A, 20 (80) A optional, multi-rate energy statistics, energy pulse output, RS485 communication interface, Modbus Protocol or DL/T 645 protocol optional. Dimensions: 76 x 89 x 74mm, 4 modules. Suitable for lighting box current, voltage measurement; single-phase energy metering.
ARD
DTSF1352 rail meter main functions: current specification 1.5 (6) A, 5 (20) A, 10 (40) A, 20 (80) A optional, multi-rate energy statistics, energy pulse output, RS485 communication interface, Modbus Protocol or DL/T 645 protocol optional. Dimensions: 126 × 89 × 74mm, 7 modulus. Three-phase energy metering for lighting boxes.
DTSD1352 rail type meter main functions: LCD display, all-electric parameter measurement (U, I, P, Q, PF, F, S); four-quadrant energy metering, multi-rate energy statistics, maximum demand statistics; current specification 1.5 ( 6) A, 5 (20) A, 10 (40) A, 20 (80) A optional, RS485 communication interface, Modbus protocol or DL/T 645 protocol optional. Dimensions: 126 × 89 × 74mm, 7 modulus. Suitable for power cabinets.
ANAPF series active power filter devices are connected to the power grid in parallel and detect harmonics and reactive components of the load in real time. PWM inverter technology is used to generate one current harmonic component and reactive component from the converter. The inversion component is injected into the power system in real time, so that harmonic control and reactive power compensation are realized.
Seven, equipment list
No.
name
Model, specification
unit
Quantity
Note
1
Power Meter
M5-B
only
3
Ankerui
ACR220EL
only
26
Ankerui
WHD48-11/HF
only
2
Ankerui
2
Monitoring Center duty room
Ankerui
Console
YT-341
set
1
Xianghe
Workstation host
IPC-610L/769VG/E5300/2G/500G/DVD/88 Mini Key+Mouse (Original Machine Standard) 2 Serial Ports
station
1
Advantech
monitor
L197WA
station
1
Lenovo
UPS power supply
C1K/1KVA
station
1
SANTAK
printer
HP 1108 A4 format
station
1
HP A
system software
Genuine Microsoft WINDOWS XP/SP3
set
1
Microsoft A
Industrial network switch
D-LINK 16 ports
station
1
D-LINK
Industrial Serial Server
NPORT5232I RS485 interface × 2 with light isolation
station
4
MOXA
Industrial switching power supply
KDYA-DG30-24K
only
4
Huali
Power Management Software
System Configuration Software Acrel-3000V6
set
1
Ankerui
Power Management Software
Data Storage Software Acrel-dbSQL
set
1
Ankerui
Power Management Software
Energy Management Software Acrel-EnerSys
set
1
Ankerui
Power Management Software
Device Driver Software Acrel-Driver
set
1
Ankerui
Photoelectric converter
Single mode photoelectric conversion HTB-1100S(25km)
only
8
3
Engineering Materials
Communication cable
Single-mode 4-core fiber
km
2
Communication cable
Shielded twisted pair RVVSP 2*0.75
km
0.2
Sail
Communication cable
BVR 1.5mm
km
4
Engineering materials
Towboards, conversion lines, lines, signs, etc.
set
1
Measuring box
A total of 4 units are required to be installed in each substation.
only
4
Fiber Optic Accessories
Includes welding, pigtails, flanges, jumpers, etc.
set
4
4
Construction and commissioning
Communication cable laying
Meter
2200
Comprehensive debugging
People/day
25
Equipment transportation costs
item
1
training fees
item
1
Construction renovation costs
item
1
references:
[1] Ankerui Electric Co., Ltd. System Solution, 2013.1.
[2] “Principles and Application Guide for Power Electronic Measurement Digital Metersâ€, Ren Chengcheng, Zhou Zhong, China Electric Power Press.
[3] Metal industry peak power limit technical guidance.
About the Author:
Xu Shuang, female, undergraduate, Ankerui Electric Co., Ltd., the main research direction for the smart grid power distribution, Email: Mobile QQ
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