Ankerui Qingqing
Jiangsu Ankerui Electric Appliance Manufacturing Co., Ltd. Jiangyin, Jiangsu 214405
Abstract : With the rapid development of the power industry and the country's increased efforts in energy conservation and emission reduction of industrial enterprises, the cost of electricity for enterprises has become an important indicator for measuring modern high-efficiency factories. The application of power management software greatly improves the utilization efficiency and management level of the company's electrical energy. This article describes the application of the Acrel-3000 power management system based on network power meters in the power management of Sinoma Cement Co., Ltd., and the system achieves distributed acquisition. And centralized control and management of intelligent, digital, networked power management.
Keywords: enterprise power management; power management system; cement;
Project Overview
Sinoblast Pingxiang Cement Co., Ltd. was established in 2008 with a registered capital of 38,881,775 yuan. It is part of China National Materials Corporation and specializes in the production and sale of cement. The company currently produces: 32.5 grades of composite Portland cement and 42.5 grades of ordinary Portland cement. Sinopec Pingxiang Cement Co., Ltd. 4500t/d clinker production line project is located in Lianqi Village, Futian Town, Shangli County, Pingxiang City. The final product is cement and clinker.
Sinoma Pingxiang Cement Co., Ltd. has built an intelligent distribution management system at the 35kV total power substation in 2011 in the new line to realize the measurement of 19 power consumption loops for the total reduction. Due to the intelligent management requirements of enterprises, scientific management of key production equipments in the entire plant area is needed, and the whole process of continuous monitoring, centralized control, and unified dispatching of power consumption of key power circuits is performed, and in accordance with national regulations and standards on energy conservation And relevant regulations of the industry, formulate energy consumption quotas for each energy-consuming department, major energy-consuming equipment and production processes (processes), and successively release the fixed amounts, and assess and reward the completion of quotas.
Sinopec Pingxiang Cement Co., Ltd. plant key distribution circuits are distributed in the 1 line high-pressure raw material room, 1 line kiln electrical room, 1 line kiln electrical room, 2 line raw material electrical room, 2 line raw material electrical room, 1 line cement Electrical rooms, 2-wire kiln tail electrical room, limestone electrical room, 2-wire cement grinding electric room, 2-wire kiln head electrical room, factory front area outdoor transformer, 1-wire residual heat electric room, 2-wire residual heat electric room, etc. 13 electrical appliances in total indoor.
Preliminary plan
1) Sinoma Pingxiang Cement Co., Ltd. has a total monthly electricity consumption of about 20 million kWh, and the power cost is relatively high. However, the energy measurement system is limited to 35kV total variability, and it lacks an overall energy measurement system and cannot cover the entire plant area. Therefore, an effective power management system needs to be established for the internal assessment management of enterprises, and based on this, the power operation parameter database will be gradually consolidated and improved, and the data will be developed and utilized at various levels (such as decision-making needs, energy analysis, and data reporting. give away). At the same time, through network technology, it has become an important subsystem of Sinosteel's Pingxiang Cement Plant informatization system, in order to realize a smart factory area and a digital factory area.
2) Part of the circuit will have a very large power in a specific period. Active power monitoring of this part of the circuit will be performed through real-time monitoring. When the power reaches a certain value (this value can be determined by the user and set), it can be alerted through audible and visual alarms. System administrators.
3) The waste heat generated by the company's production can be reused to generate power from waste heat, and statistics can be generated on this part of the loop.
4) Record the production and power consumption of the company and perform the assessment in accordance with the morning, evening and evening classes. The morning break time is 8:00am~4:00pm, the middle shift time is 4:00pm~12:00pm, and the night shift is 0:00am~ 8:00am. Comparing the data of the total substations with the power distribution room data of the production line once a week and comparing with the power consumption data provided by the power supply bureau on a monthly basis as a basis for assessing the energy consumption of each team.
Through the multi-functional power monitoring device, communication network and computer software, the entire system realizes data acquisition, operation monitoring, accident early warning, accident recording and analysis, power quality detection, and three-phase unbalanced monitoring of the enterprise power supply and distribution system during operation. And so on, to complete the company's security power supply, power management, equipment management and operation management.
Design
3.1 overall design
The distribution system of the entire company consists of 13 electrical rooms, including 15 loops for 1 line high-voltage raw materials, 11 loops for 1 line kiln electrical interior, 9 loops for 1 line kiln electrical room, and 1 line cement electrical indoor A total of 7 loops, 2-wire raw material electrical room total 25 circuits, 2-wire raw material electrical room total 4 circuits, 2-wire kiln tail electrical room total 1 circuit, limestone electrical room total 7 circuits, 2-wire cement mill Total of 21 indoor loops, 2 kiln outlets, total 20 circuits in the kiln head electrical room, 3 circuits in the outdoor transformers in the factory front area, 2 circuits in the 1 line residual heat electric indoor room, and 2 circuits in the 2 line waste heat electric indoor room, each electrical At the beginning of the design, only a part of the circuit was installed with a digital power meter. The rest of the circuits were not equipped with smart meters and did not meet the needs of enterprise intelligence. Therefore, this part of the circuit needs to be reconstructed to install a smart meter.
Based on the principle of practicability, this solution does not modify the circuits that have been installed with power meters. The system is well compatible with the power meters installed in the original power distribution cabinets. Digital multifunctions have been added to circuits that do not have smart meters installed. The meter is connected to the communication manager through the 485 bus.
3.2 Network Structure
The entire system adopts a set of Acrel3000 power management system, using a hierarchical distributed structure, namely field device layer, network management layer, and monitoring management layer, as shown in Figure 1:
figure 1
The whole set of power management system monitoring management includes power management host, printer, UPS power supply, etc. The whole system's core Acrel3000 power management software is installed in the power management host. The UPS power supply is an uninterrupted power supply. When the power supply of the equipment fails, power management can be guaranteed. The host runs normally and the power data is not lost. The monitoring center is set in the central control room of the office building. Each electrical indoor meter is connected to the ring network switch IES605-2F-2D through the 485 bus. The IES605-2F-2D has two 485 interfaces, three Ethernet interfaces and two pairs of fiber interfaces. Between each electrical room and the central control, data is transmitted through the optical fiber ring network. Optical fiber ring network is the most advanced network topology at present. Its self-healing function is good, it has strong survivability, and the stability and reliability of network transmission are high. When there is a problem in one point of the trunk line (such as somewhere on the trunk line). When the vehicle is hung up, the system can use its self-healing function to automatically switch to the standby line to keep the signal flowing.
The collection of energy data of each power circuit mainly uses the ACR and PZ series network multi-function instruments to collect the basic energy information. These data acquisition equipments can independently complete functions such as data collection, calculation, and communication. When one device has a problem, it will not affect others. The equipment is operating normally. All these devices have a 485 communication interface and can be connected to the network layer via the RS485 bus.
For each low-voltage substation more dispersed, the bottom of the smart meter with RS485 interface, network communication media using shielded twisted pair, communication protocol using Modbus communication protocol, through the RS485 bus data transmission to the ring network switch, and after construction of the light The private network uploads the data to the power management host.
The entire distribution system takes the computer station control and management system as the core, adopts modern communication technology, and manages the power consumption of the entire distribution system in a unified manner, monitors the power consumption of each link and each device in real time, and monitors and supervises power in real time. Quality, timely detection of power failure, to avoid the waste of electricity.
3.3 Software Design and System Functions
The core of the enterprise power management system is a powerful set of electricity and energy efficiency analysis management systems. It helps enterprises to fully understand the actual power consumption, power consumption environment and production efficiency level through on-line collection, processing, analysis and statistics of power consumption data. . However, the establishment of an energy management system only serves as a management tool. Enterprises need to establish an assessment system that meets the actual situation of the enterprise. The company's energy conservation goals are layered and implemented step by step, with full participation, and the energy measurement system is the foundation. Energy-saving equipment is an auxiliary and energy-saving management system is fundamental. Therefore, a partial quota and performance appraisal scheme is designed for this system:
The comprehensive energy consumption index of the whole plant is defined according to the definition in “General Principles of Comprehensive Energy Consumption Calculation†(GB/T2589-2008). The comprehensive energy consumption is divided into four types: comprehensive energy consumption, comprehensive energy consumption per unit of production value, and comprehensive energy per unit of production. Consumption and product unit output can be compared to comprehensive energy consumption, and comprehensive energy consumption must be converted into standard coal for all types of energy consumption. The conversion factor can refer to this standard.
Through the system, you can query the comprehensive energy consumption for each month or for the entire year. The relevant statements are as follows:
Formulate a performance appraisal plan for team energy use:
Data Acquisition and Management
Data acquisition and processing are the basis for the power management of the power management system. The system can capture the analog values ​​(current, voltage, power, power, frequency, and frequency) of the electrical equipment in real time and at regular intervals. The system management software can directly read the data collected by each substation smart meter through the network, and can display, count, analyze, calculate, and store all collected data. Calculate the power factor of each line in real time.
Real-time calculation of the active and reactive power values ​​of each line.
Real-time calculation of daily, monthly active power, maximum, minimum, and average reactive power.
Real-time display and statistics of the electrical value of each loop, the time-of-day billing statistics of energy data, and a variety of time-sharing (tap, peak, valley, flat value, etc.) solutions and rates depending on user requirements . Real-time display and statistics of the total value of active power and reactive power of the daily, monthly, and annual values ​​of each loop
Real-time display of capacitor switching status and manual/automatic status.
The data collection cycle, mode, parameters, etc. can be defined online by the user, and changes in the state quantity are given priority.
Information processing
Statistics, analysis, and calculation are performed on real-time data collected by the signal acquisition system, and data is periodically stored. For the same period of time as the electricity consumption unit, different electricity consumption units use the same period of time for electricity statistics; as a management platform for electricity charges, it compares with actual electricity charges.
Clearly reflects the power consumption structure of the entire company's various departments, teams and groups, and helps companies establish a reasonable power management and assessment system, and designs power consumption management reports for different teams and different workshops. For the statistics of the time of use of various electrical equipment, the energy consumption per unit of time is calculated to provide data basis for future energy transformation.
Report realized its power by the time of the query all energy data, divided into minutes, hours, days, months, years and other types, for each sub-line power meter, respectively, statistics and match the total input power line through management reports, Establish a complete energy metering system to identify blind spots and errors in power management. Energy report as shown in Figure 2
figure 2
Screen display
19-inch color LCD display as human-computer interaction interface, real-time display of various information screens of the distribution system, including the plant floor plan, a distribution system diagram, real-time parameter display, load trend query, equipment operation time, event alarm.
Figure 3 shows the low-voltage primary distribution system diagram of the infectious disease ward:
Trends in electricity usage Trends are plotted for any measurement parameter: current, voltage, power, and so on. Through the use of electricity graphs can show the peak demand situation, to find dangerous load trends or the system's remaining capacity. The load curves at different time periods can be collected or compared, and the cost of electricity consumed for each circuit of each power unit can be tracked. The trend of electricity consumption is shown in Figure 4:
Figure 4
Alarms and controls
When communication failures, telemetry violations or other alarm signals occur, the system issues an audible alarm and automatically pops up an alarm screen. The alarm must be confirmed by the operator before being reset. The alarm system is recorded in the monitoring database. When the switch is dislocated, the time alarm window and the fault related screen are automatically pushed out, the displacing switch in the screen flashes, and the discoloration prompts and there is an alarm statement and the current state of the disposition in the alarm box, and indicates the name of the disposition switch. , running number and nature (normal operation or accident trip). When the current/voltage over-limit occurs, the screen flashes and the current limit value is displayed in the alarm message box. The monitoring system automatically stores historical data and historical events. The user can customize the query according to the device, data type, time period, and other items. In addition to computer alarms, the system also has special sound and light alarms to remind duty personnel. The alarm interface is shown in the figure below:
4 Conclusion
The Acrel300 power management system used in this project was officially put into operation in 2014. The entire system is stable and safe. The system installs multi-function electricity meters for each key power circuit, establishes a power management system, formulates a performance appraisal program for energy use, and provides a large amount of real-time and accurate measurement of electricity consumption for key power circuits through computer networks and information technology. Power data, to find out the energy flow, understand the energy composition, and provide the data basis for internal measurement assessment and safe electricity use by the various types of charts and reports provided by the power management software, so that the user can find the energy is not Reasonable, guide users to carry out targeted management measures and energy-saving improvement measures.
references
[1]. Ren Chengcheng, Zhou Zhong. Principles and Application Guide for Digital Meters for Electric Power Measurement [M]. Beijing. China Electric Power Press, 2007. 4
[2].Zhou Zhong. Application of Power Meters in Energy Metering of Large-scale Public Buildings [J]. Modern Building Electronics 2010. 6
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