Xu Shuang Ankerui Electric Co., Ltd., Shanghai Jiading 201801 I. Analysis of power consumption characteristics of users in the industry The general and special equipment manufacturing industry can be subdivided according to the national production industry: boiler and prime mover manufacturing, metal processing machinery manufacturing, hoisting and transportation equipment manufacturing, manufacturing of pump valve compressors and similar machinery, bearing gearing and drive components. Manufacturing, furnace and electric furnace manufacturing, fan weighing equipment, packaging equipment and other general equipment manufacturing, metal casting and forging manufacturing; mining and metallurgy building equipment manufacturing, chemical wood non-metal processing equipment manufacturing, food and beverage tobacco and feed production equipment manufacturing, Manufacture of special pharmaceutical equipment for printing and pharmaceutical production, special equipment manufacturing for textile and clothing and leather industry, manufacturing of special equipment for electronic and electrical machinery, manufacturing of machinery for agriculture, forestry, animal husbandry and fishery, manufacture of medical instruments and equipment, and manufacturing of environmental protection and public safety and other specialized equipment, etc. Manufacturing Industry. The scope of general and special equipment manufacturing is particularly wide, and basically belongs to non-continuous production units. There are a large number of users in the general and special equipment manufacturing industries. The load ranges from tens of kilowatts to several thousand kilowatts, and individual companies even exceed 10,000 kilowatts. The industry's user production time is from 8:00 to 21:00, there are also 24 hours of continuous production. The early peak time period is the peak of production and peak electricity consumption throughout the day; the lowest production in the late night is the low electricity consumption. The peak-to-peak difference in electricity consumption is particularly large, and the daily load curve is a typical “middle high, two low†form. The load curve of a small number of continuous-use general and special equipment manufacturing users is relatively stable, with around 20% fluctuations. 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 the whole year, the annual electricity consumption curve of this type of enterprise shows high summer and winter load, and small load in spring and autumn. Among them, the highest probability of annual maximum load occurs in summer. General and special equipment manufacturing industry user equipment classification table category Major equipment Note Non-productive load Office lighting, computer fax printing and other office appliances, split and central air-conditioning, cafeteria rice cooker, blower, road lighting, electric water heater general Auxiliary production load Production equipment air conditioners, fans, production equipment air conditioners, cooling pumps, fans, fans, general The main productive load Heat treatment furnaces, melting furnaces, high frequency furnaces, casting machines, welding machines, wire drawing machines, melting furnaces, lathes, milling machines, planer machines, punch presses, drill presses, air hammer machines, air compressors, cutting machines, shears, spray painting machines, Dryer, electroplating machine, CNC machine tool, blower, boiler, water pump, crane, galvanizing machine, production line, assembly line, etc. More important Safeguarding load CNC machine tools, workshop lighting, fire protection and security equipment important It can be seen from the main power equipments of general and special equipment manufacturing users that the vast majority of electrical equipment of this type of users can interrupt power usage, and the load limit ratio can be 80 to 90%. II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability 1. In order to ensure the people's livelihood and the safe operation of the power grid, when there is a gap in the power grid, users of general and special equipment manufacturing industries may be given peak-to-peak power cuts. 2. It is determined by the characteristics of users of general and special equipment manufacturing that can interrupt the production load and the number of users in the general and special equipment manufacturing industries. The users of general and special equipment manufacturing industries are avoiding the peaks except steel, cement, and high energy consumption enterprises. The key industry. 3. As long as the user of the general and special equipment manufacturing industry notifies in advance (15 to 30 minutes) that the measures are in place, they can fully act as the main force for the peak load limitation. 4. The advantages of users of general and special equipment manufacturing industries participating in peak load limitation 1) Power cuts only reduce production without causing damage and damage to personnel and equipment. 2) The ratio of electricity restriction can be very large. Spring, autumn and winter can be limited to 80%~90% of real-time electricity load. 3) The peak load can be “faster and fasterâ€. 5. The users of the general and special equipment manufacturing industries are involved in the unfavorable aspects of peak load shifting and power limiting: 1) Since the load of each household is not large, the effect of limiting electricity is not obvious. To constrain a certain number of loads, a considerable number of users are required to participate. 2) Because the load of each household is not large, the effect of shifting peaks on daily schedules and rest days is not obvious, but the number of affected people is large, and there are many safety problems in organizing transportation and women workers to work. 3) The per capita electricity load in the industry is low, and a load of 10,000 kilowatts per load will result in 3,000 to 5,000 workers failing to work. If the electricity is limited for a long time and the cycle is frequent, it may cause problems. 4) When the temperature is higher than 32°C, electricity is limited, and some ventilation and cooling load are required in the plant. 6. Method of staggering the peak of industry users For the general and special equipment manufacturing industry, most of the electrical equipment can participate in peak-to-peak power cuts. The main methods of shifting peaks are: 1) Set the air conditioner temperature at 26 °C ~ 28 °C; 2) Reduce some of the lighting, office air conditioning load, etc.; 3) Adjust the time of commute to avoid the situation of no electricity after the peak hours of electricity restriction; 4) The main equipment is scheduled to be used during peak load hours for maintenance; 5) Emissions or holiday breaks (one week of production or one week of production shutdown; three stops or three stops may be implemented); 6) Shut down some electrical equipment. 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-displacement index, while retaining the basic security load, combined with its own production process, it can selectively release part of the equipment load at different times. 2. Emergency peak shift: After receiving the peak load instruction, it is necessary to quickly put the load into limit, and then gradually release the load according to the instruction to resume normal production. The electrical equipment that can be parked at this level are: electric water boilers, road lighting of the factory, canteens, dormitories, office air conditioners, office lighting, office elevators, plant lighting, plant air conditioners, lathes, milling machines, planers, punch presses, drill presses, and spray painting machines. , Air Hammer, Air Compressors, Cutting Machines, Shears, Dryers, Electroplating Machines, Cranes, Welders, Wire Drawing Machines, Galvanizers, Blowers, etc. (II) Gap Level III Participation Plan 1. Staged peak shift: 1) In the peak load shifting period, firstly input the peak load with limited load and high response time, and load the equipment with limited time; at the same time, gradually input the limited load with slow response time, ensure that all limit load can participate in the peak shift; 2) 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, it can selectively release part of the equipment load at different times. 2. Emergency peak shift: After receiving the peak load instruction, it is necessary to quickly put the load into limit, and then gradually release the load according to the instruction to resume normal production. The electrical equipment that can be stopped at this level are: heat treatment, melting furnace, high-frequency furnace, spray paint machine, dryer, electroplating machine, lathe, milling machine, planer, punch, drilling machine, air hammer machine, air compressor, cutting machine, Shears, water heaters, street lighting, canteens, dormitories, office air conditioners, office lighting, office elevators, factory lighting, plant air conditioners, blowers, boilers, water pumps, cranes, welding machines, wire drawing machines, galvanizing machines Wait. (III) Level II Participation Scheme for Gap 1. Staged peak shift: 1) In addition to retaining the basic security load, invest all the time in the peak load; 2) For equipment with slow response time, make sure to participate in the preparation for shifting peaks in advance and ensure that all limitable loads can participate in the peak shift at full time. 2. Emergency peak shift: After receiving the peak load instruction, it is necessary to quickly put the load into limit, and then gradually release the load according to the instruction to resume normal production. The electrical equipment that can be stopped at this level are: heat treatment, melting furnace, high frequency furnace, spray paint machine, dryer, electroplating machine, lathe, milling machine, planer, punch, drilling machine, air hammer machine, air compressor, cutting machine, Shears, factory road lighting, office air conditioning, office lighting, office elevators, plant lighting, plant air conditioners, blowers, boilers, water pumps, cranes, canteens, dormitories, electric water heaters, welding machines, wire drawing machines, galvanizing machines , CNC machine tools, production lines, assembly lines and so on. (IV) Gap Level I Participation Plan 1. Staged peak shift: In the gap class I level, the general and special equipment manufacturing industry should achieve a peak-to-peak limit by the method of “opening three stops per weekâ€, the method of “one week of production shutdown a week†and the “shifting all production shifts to night productionâ€. Electricity. 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. Sudden power outages may result in unbalanced traffic during work, possible tilting and falling off, damage to the body itself and facilities for scrapping the ground. Workers may also be injured, causing 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. 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 5.1 Project Overview Wuhan Heavy-duty Machine Tool Group Co., Ltd. (formerly Wuhan Heavy-duty Machine Tool Plant, referred to as Wuzhong) is a large-scale backbone enterprise that produces the largest and most complete variety of heavy-duty and super-heavy machine tools in China. Heavy-duty machine tool products all realize numerical control. Most products have reached the international level of the 1990s, super heavy-duty CNC vertical lathes, super-heavy horizontal lathes, ultra-heavy CNC Gantry mobile boring and milling machines to reach the international advanced level. It is also the only manufacturer in the world that can produce a variety of super-heavy duty machine tools. Ankerui Electric Co., Ltd. undertakes the design and implementation of the remote automatic meter reading system project of Wuhan Heavy Machine Tool Group. Acrel-3000 power monitoring system is adopted. The monitoring range of this monitoring system is: Weitai Liquor Company, CNC Boring Machine Company, CNC Milling Machine Company, Wuhan Shanfu Company, Wuzhong Casting and Forging Company, large-scale processing factory, small and medium-sized processing factory, Office building 8 units 13 power meters in the distribution room. In accordance with the actual needs of Wuhan Heavy Machine Tool Group and the functions of intelligent components, the design of the system is completed. The main functions are: display of a main wiring diagram interface; remote parameter measurement of electric parameters and over-limit alarm of electric parameters; event recording, abnormal monitoring of system operation; Alarm and operation records; power report query and printing; system load, real-time harmonics, historical curves, user rights management and other main functions, the actual refinement function sellers can make feasibility changes according to the buyer's habits and needs. The entire system adopts a network distributed structure. The monitoring host is located in the 10KV monitoring room. The system adopts an open communication protocol and is connected to the communication server MOXA NPort 5430.13 power distribution rooms through the field bus. It is connected to the low-voltage distribution system through optical fiber networking to achieve Data communication function. 5.2 System Structure The system adopts a layered distributed computer network structure, namely, a bay layer, a communication layer and a station control layer as shown in the following figure: The main equipments in the bay are: multi-functional network power meters, switches, analog acquisition modules and intelligent circuit breakers. 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 middle tier is mainly a communication server. Its main function is to collect the scattered data at the site collection device and transmit it to the station control layer at the same time. The data exchange between the field layer and the station control layer is completed. Station control layer: equipped with high-performance industrial computers, monitors, UPS power supplies, printers, audio 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, and RS485 adopts shielded wire transmission. 5.3 The main functions of the system 1 Data Acquisition and Processing Data acquisition is the basis of power distribution monitoring. Data collection is mainly completed by the underlying multi-function network instrument to achieve local real-time display of remote data. The signals that need to be collected include: three-phase voltage U, three-phase current I, frequency Hz, power P, power factor COSφ, power Ep, and remote device operating status. Data processing is mainly to display the electrical parameters collected according to requirements in real time and accurately to the user, so as to meet the requirements of automation and intelligence of the power distribution monitoring. At the same time, the collected data is stored in the database for user query. 2 man-machine interaction The system provides simple, easy to use, and good user interface. Using the Chinese interface, the CAD graphic shows the electrical main wiring diagram of the low-voltage power distribution system, shows the status of the power distribution system equipment and the corresponding real-time operating parameters; dynamic refresh of the screen in real time; analog display; switch display; alarm log display. 3 fault alarm and accident recall When an operational fault occurs in the power distribution system, an alarm will be sounded in a timely manner to prompt the user to respond to the fault circuit in a timely manner. At the same time, the time and place of the event are automatically recorded to be queried by the user and the cause of the fault is recalled. 4 database establishment and inquiry It mainly completes remote measurement and remote signal acquisition, and establishes a database to generate reports regularly for users to query and print. 5 Energy cost management Automatically carry out daily, monthly, and annual energy statistics, you can set the peak, peak, level, and valley time, realize the time-of-day billing function, generate daily, monthly, annual reports, and current curves. 6 user rights management The number of users who can add and remove software according to the buyer's requirements and set the user's rights. For different levels of users, different permission groups are set to prevent the losses caused by human misoperation to production and life, and to realize the safe and reliable operation of the distribution system. 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) ACR220EL power meter with low voltage contact or outlet loop 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 Network instrument ACR220EL only 100 Ankerui Open type current transformer AKH-0.66 Series only 88 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] Technical guidance for peak and power cuts in general and special equipment manufacturing industries. About the Author: Xu Shuang, female, undergraduate, Ankerui Electric Co., Ltd., the main research direction for intelligent power monitoring and power management system, Email: mobile phone Shandong Jianlong Special Steel Co., Ltd. , https://www.jianlongsteelpipe.com.gif)
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