Application of Power Demand Side Management and Intelligent Power Monitoring Technology in Peak Load Limitation and Electricity Limitation in Transportation Equipment Manufacturing Industry

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

The transportation equipment manufacturing industry can be subdivided into the following 34 manufacturing industries according to the national production industry: railway transportation equipment manufacturing, railway rolling stock and EMU manufacturing, industrial and mining rail vehicle manufacturing, railway rolling stock manufacturing, railway equipment and equipment ,parts manufacture,manufacture of ships and floating devices,metal shipbuilding,non-metallic shipbuilding,building and repair of recreational boats and sports boats,building of marine ancillary equipment,ship repairs and ship recycling, navigation equipment and other floating devices,other transportation There are 34 manufacturing industries such as equipment manufacturing.

The scope of the transportation equipment manufacturing industry is relatively extensive and basically belongs to non-continuous production units. The number of users of the transportation equipment manufacturing (shipbuilding) industry is relatively large. Loads range from tens of kilowatts to several thousand kilowatts, and individual companies even exceed 10,000 kilowatts.

Users in this industry usually have production time from 8:00 to 21:00, and also have continuous production for 24 hours. The general early morning time period is the peak of production and peak electricity consumption throughout the day; the lowest production in the late night is the low period of electricity consumption. The peak-to-peak ratio of electricity consumption is particularly large, and the daily load curve is a typical “middle high, two low” form. The load curve of a small part of the continuously manufacturing transport equipment manufacturing users is relatively stable, and the load fluctuation is about 20%. In high temperature or cold season, with the change of temperature, the electricity demand of this kind of enterprises also rises significantly with the use of air conditioners. From a year-round perspective, the annual electricity consumption curve of this kind of company shows the characteristics of “high summer and winter load” and “small load in spring and autumn”. Among them, the highest probability of annual maximum load occurs in summer.

Transportation equipment manufacturing industry user equipment classification

category

Major equipment

Note

Non-productive load

Office lighting, office lifts, computer fax printing and other office appliances, split and central air-conditioning, cafeteria rice cookers, blowers, water heaters, street lighting, dormitory and so on.

general

Auxiliary production load

Production equipment air conditioners, fans, cooling pumps, ventilators,

general

The main productive load

Welders, cranes, blowers, heat treatment furnaces, melting furnaces, high frequency furnaces, spray painters, dryers, cutting machines, shears, electroplating machines, hammers, air compressors, pumps, lathes, milling machines, planers, Punch, drilling machines, CNC machine tools, boilers, wire drawing machines, galvanizing machines, pipe bending machines, polishing machines, setting machines, production lines, assembly lines, etc.

important

Safeguarding load

Waste gas recovery suction fan, workshop lighting, firefighting and security equipment

important

II. Analysis of industry users' ability to participate in peak-to-peak power limiting

1. In order to protect people's lives and the safe operation of the power grid, when there is a gap in the power grid, users of the transportation equipment manufacturing industry can perform peak-to-peak power cuts.

2. It is determined by the characteristics that the users of the transportation equipment manufacturing industry can interrupt the production of the load and the number of users of the transportation equipment manufacturing industry. The users of the transportation equipment manufacturing industry should be the key industry that avoids peaks in various places.

3. As long as the users of the transportation equipment manufacturing industry are notified in advance (15 to 30 minutes) and the measures are in place, they can fully act as the vital force for the peak load limitation.

4. It can be seen from the main power equipment of the users of the transportation equipment manufacturing industry that most of the power consumption equipment of this type of users can interrupt the use of electricity, and the load limit ratio can be 60 to 70%.

5. The advantages of users involved in transportation equipment manufacturing in participating in peak load shifting and power limiting:

6. The users of the transportation equipment manufacturing industry are involved in the unfavorable aspects of peak load limitation and power limitation:

7. The method of shifting peak users in the transportation equipment manufacturing industry

For the transportation equipment manufacturing industry, most of the electricity-consuming equipment can participate in peak-to-peak power cuts, and the main methods of shifting peaks are:

Third, the industry users involved in the peak load limitation technology program

(A) gap level IV participation program

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, combined with its own production process flow, it can selectively release part of the equipment load at different time periods.

2. Emergency peak shift

After receiving the peak-to-peak instruction, it is necessary to quickly invest the load, and then gradually release the load according to the instructions to resume normal production.

The electrical equipment that can be parked at this level are: electric boiling water heaters, street lighting, canteens, dormitories, office air conditioners, office lighting, office building elevators, factory lighting, plant air conditioners, electric welders, pipe benders, polishing machines, setting machines. , lathes, milling machines, planers, punches, drill presses, air hammer machines, air compressors, cutting machines, shears, paint sprayers, dryers, electroplating machines, cranes, cranes, wire drawing machines, galvanizing machines, blowers, etc. .

(B) gap level III participation program

1. Staged peak shift:

2. Emergency peak shift

(III) Level 2 Participation Scheme for Gap Level

1. Staged peak shift:

2. Emergency peak shift

(IV) Gap Level I Participation Plan

1. Staged peak shift:

When the gap level is Class I, the transportation equipment manufacturing industry should implement peak-to-peak power cuts by using the method of “opening three stops four times a week”, “making a week off a week of production”, and shifting “production shifts to nightly production”. .

2. Emergency peak shift:

Stop all electrical equipment and all production lines outside the security within 15-30 minutes.

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

1. In the event of a sudden power outage, the traffic during work will lose its balance and will be tilted or shed. The body itself may be damaged or scrapped. Ground facilities and operators may also be injured, resulting in damage and casualties.

2. Some equipment and facilities in high-precision numerical control equipment, sudden power failure will cause system data loss, product scrap, equipment serious damage, restore normal production takes a long time, resulting in major economic damage.

3. In the event of a sudden power outage of equipment such as melting furnaces, high frequency furnaces, boilers, etc., the furnace will be scrapped, the molten metal solution will be scrapped, and there will be hidden dangers of fire.

4. The sudden power failure of the shipbuilding industry users will result in the interruption of ventilation and lighting in the cabin and prone to gas welding poisoning and personnel drop accidents.

Therefore, when the industry participates in the peak of change, 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 minimize losses.

V. Functions and Applications of Intelligent Power Monitoring

Wuxi Auto Parts Co., Ltd. project includes high pressure and low pressure. Its high-voltage distribution system includes two 10kV incoming lines and two metering cabinets, two voltage transformer cabinets, two high-voltage outlet cabinets, and one contact cabinet. Acrel3000 power management system realizes remote monitoring of high-voltage, low-voltage inlet, connection and outlet circuits in the power distribution room. The high- and low-voltage power distribution systems are placed in the same electrical room, and the monitoring host and communication cabinet are placed in this electrical room.

5.1 Network Structure Topology

The specific form of each structural layer is as follows:

(1) Master Station (Station Control Management)

Located in the monitoring room, specifically including: back-end hosts and other related peripherals with power management system installed. Responsible for unpacking the data uploaded by the communication interval layer, performing centralized management and analysis, performing related operations, and being responsible for the overall monitoring of the entire power distribution system. The intelligent power monitoring system provides dedicated communication function modules, and sends relevant data and information to the next-level system (such as BAS, DCS, or dispatch system) via OPC or other communication protocol through a dedicated Ethernet hardware communication interface to implement the system. Integration.

(2) Communication bay layer (network communication layer)

The communication manager is used to communicate with various devices on the field device layer, collect data and parameters of various devices, process the packet and transfer them to the master station layer, and at the same time as the relay unit, accept the instructions issued by the master station layer. , forwarded to the field device layer devices.

(3) Field device layer

Located in the low-voltage transmission and distribution site, including: ACR multi-function power meter, M5 series comprehensive protection, WHD series temperature and humidity controller, responsible for collecting all kinds of data and information status of the power field, sent to the communication interval layer, but also as The execution unit executes various instructions issued by the communication interval layer.

 

5.2 Implementation Features

Acrel-3000 energy management system can collect real-time and time-sequenced parameters of each field device's electrical parameters and switch status (including three-phase voltage, current, power, power factor, frequency, power, switch position, equipment operation status, and important circuit harmonics. Wave bar graph, etc.), directly display the collected data, or generate new intuitive data information through statistical calculations (represented in the total system power, harmonics, and power factor upper and lower limits, etc.), and perform important database information storage.

The power distribution system has a CAD single-line diagram showing the wiring of the low-voltage distribution network. The main screen can visually display the operating status of each loop, and has the functions of live, uncharged and fault-colored circuits. The main electrical parameters are directly displayed on the human-computer interaction interface and refreshed in real time.

1. Database management software uses mainstream, universal, high-performance professional real-time/history databases and enterprise-level relational databases to store data. Data management software has open, comprehensive, and integrated information management methods. Strict rights management functions can set different operation passwords and passwords according to different management roles, grant different database access rights, and provide database entity access audit mechanisms to maintain database information in different roles.

2, data integrity and security is extremely critical, provide a variety of security protection mechanisms, provide data encryption technology of the Internet database, provide data encryption technology from the hard disk transfer to the back-end system process, to ensure data security.

3, the database provides data protection technology, can use the transaction mechanism to automatically back up the database and record data backup log. Provide data repair technology to repair data in a timely manner in the event of database corruption and maintain data integrity.

4, the system provides real-time database and historical database in two parts, real-time / historical database processing capacity to reach 100,000 points / second or more throughput, memory in all data collected in 1 second, the historical database storage compression ratio to achieve Above 30:1, the historical database data retention period is not less than 10 years.

The system provides real-time curve and historical trend analysis of the two curves interface, by calling the relevant circuit real-time curve interface to analyze the current load running status of the circuit. For example, by invoking the real-time curve of a given loop, the signal fluctuation caused by the electrical equipment of the loop can be analyzed. The historical trend of the system is that the system can view its historical trend for all stored data, facilitating the quality analysis of the monitored distribution network by the engineering personnel.

The system has a standard power report format and can be designed to meet the needs of the report format according to user needs, the system can automatically statistics. Various types of real-time running reports, historical reports, event failure and alarm record reports, operation record reports, etc. can be generated automatically. All data values ​​recorded by the system can be queried and printed, and the hourly, daily, monthly and annual reports of electric energy can be generated automatically. According to the time period of multi-rate and the set value of rate, the rate report of energy generation can be generated. The parameters such as the start point and interval of query printing can be set by themselves. The system design can also customize the report output function that meets different requirements according to the needs of users.

The system can be set to trigger an alarm when a power quality event occurs, the measured value is exceeded, and the device status changes. When the system alarms, information voice prompts can be provided to automatically pop up alarm screens or trigger necessary operations. At the same time, relevant personnel can be notified.

 

This software can give different levels of users different permissions to ensure the security and reliability of the system during operation. For example, if an operator is required to enter an operation password for an important loop, the user must enter the confirmation password before completing the operation.

Sixth, the main monitoring products

(1) 10KV outlet loop selection ACR330ELH instrument

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.

(2) ACR220E power meter selected for low voltage outlet circuit

The main functions of this table are: LED display, all-electric parameter measurement (U, I, P, Q, PF, F); four-quadrant energy metering; 2DI+2DO; RS485 communication interface, Modbus protocol.

Dimensions: 96 x 96mm, opening size: 88 x 88mm.

 

(3) Energy-saving product optional rail table or APF active filter device

Lighting box DTSF1352 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. Suitable for lighting box current, voltage measurement; three-phase energy metering.

 

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 reverse component is injected into the power system in real time, so that harmonic control and reactive power compensation are achieved.

Seven, equipment list

No.

name

Model, specification

unit

Quantity

Note

1

Power Meter

　

　

　

　

 

Three-phase electric energy meter

ACR330ELH

only

15

Ankerui

 

Three-phase electric energy meter

ACR220E

only

20

Ankerui

 

Current Transformer

AKH-0.66/I

only

105

Ankerui

 

WHD series temperature and humidity controller

WHD96-11

only

10

Ankerui

 

M5 Series Medium Voltage Protection Device

M5-F

only

2

Ankerui

2

Monitoring Center duty room

　

　

　

　

 

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] Principle and Application Guide for Power Electronic Measurement Digital Instrument Ren Chengcheng, Zhou Zhong, China Electric Power Press, 2004.4.

[3] The peak load shifting and power limiting technical guidance for the transportation equipment manufacturing industry.