Power Demand Side Management and Intelligent Power Monitoring Technology Applied in Peak Load Limitation and Electricity Limitation in Rubber Industry

Xu Shuang

Ankerui Electric Co., Ltd., Shanghai Jiading 201801

I. Analysis of electricity consumption characteristics of users in the industry

According to the national production industry, the rubber industry can be subdivided into: tire manufacturing (including tire manufacturing for vehicles, aircraft and construction machinery, tire manufacturing, tire retreading and processing), rubber sheets, tubes and belts, rubber parts manufacturing, and recycling. Rubber manufacturing, daily and medical rubber product manufacturing, rubber boot shoe manufacturing, and other rubber product manufacturing. Other rubber products manufacturing companies include: rubber waterproofing membrane enterprises (chloroprene rubber waterproofing membranes, polyvinyl chloride rubber blended waterproofing membranes, EPDM rubber waterproofing membranes and other enterprises), inflatable rubber products enterprises (rubber pontoons, Rubber balloons, rubber lifebuoys, rubber airbags, rubber shock absorbers, rubber fenders, rubber air springs, Kotra Rao rubber joints, etc.), hard rubber and its products companies (hard rubber, battery slots, hard rubber waste Scraps, adhesive tapes, and other adhesive tapes, users of this industry currently have a high degree of automation applications.

The industry is generally powered by 35kV or 10kV substations. The electricity load is medium, generally less than 5,000 kilowatts. The production nature is three-shift continuous operation.

Rubber industry user equipment classification

II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability

1. The users in this industry are generally 24 hours continuous production, and their load curves are relatively stable, generally differing by about 10%. During the high temperature or cold season, the electricity demand of these enterprises has also changed. With the change of temperature, the electricity load will increase significantly. From a year-round perspective, these enterprises have the characteristics of “high summer and winter loads, and small loads in spring and autumn”.

2. The emergency peak load shifting and power cutoff may disable the non-productive load and part of the auxiliary production equipment load, and will quickly respond to the peak load change. The industry has a moderate electricity load, and the effect of emergency peak load limiting is generally low.

3. During the stage of peak phase shift, users in this industry can effectively carry out the production of power cuts for part of the production lines. Phased peak offsets are effective.

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-disappearance index, while retaining the basic security load, a production line (extruder, calender, bead machine, cutting machine) can be selectively released over a period of time in combination with its own production process. Molding machines, inspection machines, etc.) and other production loads. Three quarters of production methods are used to limit electricity.

2. Emergency peak shift:

After receiving the peak shift instruction, it is necessary to rapidly disable non-productive loads such as air conditioners, fans, and lighting, and gradually release the load according to the instructions to resume normal production.

(II) Gap Level III Participation Plan

1. Staged peak shift:

Under the premise of executing the peak-shifting instructions and completing the peak-disappearance index, while retaining the basic security load, it can selectively release two production lines (extruder, calender, bead machine, cutting machine) in combination with its own production process. Molding machines, inspection machines, etc.) and other production loads. Use half production to limit electricity.

2. Emergency peak shift:

Based on the implementation of the IV-grade plan, under the premise of executing the peak-shifting instructions and completing the peak-disappearance indicator, while retaining the basic security load, it is also possible to selectively disable the water pump, cooling tower, and air compressor in combination with its own production process. Freezers and other auxiliary production loads.

(III) Level II Participation Scheme for Gap

1. Staged peak shift:

Under the premise of executing the peak-shifting instructions and completing the peak-disappearance index, while retaining the basic security load, it is also possible to selectively disable three production lines (extruder, calender, bead machine, cutting machine) in combination with its own production process. , molding machines, inspection machines, etc.) and other production loads. A four-molecule production method is used to limit electricity.

2. Emergency peak shift:

On the basis of the implementation of the Level III program, under the premise of executing the peak-shifting instructions and completing the peak-disappearance index, while retaining the basic security load, it can selectively disable the water pump, cooling tower, and air compressor in combination with its own production process. Freezers and other auxiliary production loads.

(IV) Gap Level I Participation Scheme

1. Staged peak shift:

Under the premise of executing the peak-shifting instructions and completing the peak-displacement index, while retaining the basic security load, the entire production line can be selectively decommissioned for a period of time in combination with its own production process (extruder, calender, bead machine, cutting machine). , molding machines, inspection machines, etc.) and other production loads. Power cuts are applied to stop production.

2. Emergency peak shift:

Based on the implementation of the Level II program, under the premise of executing the peak shifting instruction and completing the peak shifting factor, while retaining the basic security load, the water pump, cooling tower, and air compressor can be selectively deactivated in combination with the inspection process. Machines and other auxiliary production load.

Fourth, the industry users involved in the peak load shifting risk and precautions

1. In the event of a sudden power outage, the internal mixer may cause combustion and lead to fire. Its electricity load accounts for 30% of the total equipment power consumption;

2. Extrusion machines and other equipment will cause rubber hardening and damage the equipment after a sudden power failure;

3. After the power failure is notified, the equipment can be completely powered off within 1 to 2 hours;

4. If continuous production is required when the load is insufficient, use the reduced supply power;

Therefore, when the users of the industry participate in the peak shift, enterprises should, according to their own actual conditions, formulate internal emergency plans scientifically and reasonably, actively cooperate with the peak implementation, eliminate the occurrence of malignant accidents, and take initiative to assume social responsibilities while minimizing losses.

V. Functions and Applications of Intelligent Power Monitoring

There is a total of 10 electric power distribution cabinets in Qingdao, a total of 10 electric power distribution cabinets, 28 surface 0.4 kV power distribution cabinets, and a total of 115 high and low voltage circuits. There is no monitoring device on the 10 kV arrester cabinets, so the system monitors the working status of 114 circuits. T1 and T2 transformers are provided with a bus connection between the transformer circuits, and an 800kVA diesel generator is provided to supply power for some important loops under emergency conditions. The T3 transformer circuit is used alone.

The line and feeder of the 10kV circuit are equipped with M5 series medium voltage protection device to collect the conventional electrical parameters and switch status of the 10kV circuit; the 0.4kV line and the parent circuit are equipped with ACR330ELH network quality analyzer, and the conventional electrical parameters of the acquisition circuit. , Four-quadrant electrical power and grid quality parameters; 0.4kV feeder circuit is equipped with ACR220E series multi-function power meters, collecting the conventional electrical parameters and four-quadrant electrical degrees of the circuit. In addition, all 0.4kV feeder circuits use the ARCM series four-circuit leakage monitoring instrument for residual current monitoring.

5.1 Network Structure Topology

The field device layer power meters are respectively installed on the corresponding distribution circuit according to the design requirements. RS-485 interface to achieve data exchange with the host computer system. The communication specification of the multifunction meter and the leakage meter is approximately Modbus-RTU, the communication protocol of the protection device is approximately IEC60870-5-103, and the communication management layer consists of two Nport-5630 serial port servers and one switch, and eight of the actual projects are used. 485 serial port, the remaining 8 serial ports are spare. The serial server converts the RS-485 bus protocol to an industrial Ethernet protocol, and connects to the station control management host through TCP/IP to build the data link. The communication management equipment is installed in the operator's operation desk of the electrical duty room and is installed together with the station control management equipment. The station control management equipment is the North China industrial control host, monitor, HP printer and Shante UPS power supply, all installed on the electrical duty. Room console. Acrel-2000 power monitoring system software installed on the host computer realizes the collection, processing and various human-machine interaction functions of field instrument data.

5.2 System Functions

5.2.1 System main interface

Under the power distribution monitoring module, the working status of 1# transformer, 2# transformer, 3# transformer, 10kV loop and the communication status of all instruments can be queried. The status of all current instruments can be viewed through the instrument communication status chart. The low-voltage multi-function instrument is not equipped with a switch quantity acquisition function. Since the auxiliary power line of the instrument is taken from the lower end of the circuit breaker, the communication status of the instrument also represents the closing and closing status of the circuit.

5.2.2 Distribution Display Interface

10kV and 0.4kV distribution room distribution circuit operating status of the power distribution circuit is displayed in a one-time diagram, and the monitoring information such as voltage, current, power, power factor, and frequency can be visually and dynamically displayed in a single graph, which satisfies the on-site requirements.

5.2.3 Report Function

Through the report function, it can inquire about the general electric parameter data of the main circuit at any moment, the power consumption of the low voltage circuit, the leakage current value of the low voltage feeder circuit, and the temperature value of the distribution cable.

5.2.4 Trend Curve

Curve trend: Achieved the user through the current draw trend curve for each distribution circuit, analysis of the circuit distribution operating conditions. The measurement data range can be set in the curve to facilitate viewing. The curve can also set the start time and time interval, which is convenient for the user to view the curve at any time.

5.2.5 Event Recording and Failure Alarm

Distribution circuit overload, residual current in the low-voltage circuit is too large, real-time alarm and history alarm inquiries of 10kV circuit switching, etc., as shown in the figure, list the alarm occurrence and recovery time, loop name, loop number, data Data of points, alarm contents and alarm values ​​shows that certain circuit residual current values ​​are exceeding the standards.

Sixth, the main monitoring products

(1) ACR330ELH meter for high voltage circuit or low voltage circuit

The meter is a power quality analyzer. The main functions are: LCD display, all-electric parameter measurement (U, I, P, Q, PF, F, S); four-quadrant energy metering, multi-rate energy statistics; THDu, THDi, 2-31 times each harmonic wave component; Voltage crest factor, telephone waveform factor, current K factor, voltage and current unbalance degree calculation; Grid voltage and current positive, negative, zero sequence component (including negative sequence current) measurement; 4DI+ 3DO (DO3 overvoltage, undervoltage, overcurrent, unbalance alarm); RS485 communication interface, Modbus protocol or DL/T645 protocol. Dimensions: 120 × 120mm, opening size: 108 × 108mm. Suitable for high pressure important circuit or low voltage inlet cabinet.

(2) ACR220E power meter with low voltage contact or outlet loop

The main functions of this table are: LED 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 ARCM series

The main functions are: residual current detection, temperature detection, LCD display, RS485 communication interface, Modbus protocol. Relay output, digital input function.

(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) Optional A, 5 (20) A, 10 (40) A, 20 (80) A, 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 can be realized.

Seven, equipment list

No.

name

Model, specification

unit

Quantity

Note

1

Power Meter

M5-B

only

Ankerui

ACR330ELH

only

20

Ankerui

ACR220E

only

50

Ankerui

ARCM200BL-J4

only

twenty one

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 Meters", Ren Chengcheng, Zhou Zhong, China Electric Power Press.

[3] Rubber 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

Jilin Province Xuan Yi Trading Co.,Ltd. , https://www.xytruckparts.com