Application of Power Demand Side Management and Intelligent Power Monitoring Technology in Peak Load Limitation and Power Limiting in Plastic Products Industry
Xu Shuang Ankerui Electric Co., Ltd., Shanghai Jiading 201801 I. Analysis of power consumption characteristics of users in the industry The plastic products industry can be subdivided into plastic film industry, plastic sheet, pipe and tube manufacturing, plastic wire, rope and braid manufacturing, foam plastics, plastic artificial leather, synthetic leather manufacturing, plastic packaging and Container manufacturing, plastic parts manufacturing, daily plastic manufacturing (plastic shoes manufacturing, daily plastic sundries manufacturing), and other plastic products manufacturing. The industry is generally powered by 10kV substations and 0.4kV, and its electricity load is medium, generally about 2,000 kilowatts or even less; the production nature is generally three-shift continuous operation. Plastic product industry user equipment classification category Major equipment Note Non-productive load Computers, cold storage air conditioning, cafeteria rice cookers, blowers, plant road lighting, fans, lighting, most computers and printers, copiers, scanners, electrical equipment, living water pumps, street lights, door alarm. general Auxiliary production load Fans, air compressors, cooling towers, air conditioners, traffic, elevators, general The main productive load Plastic grinders, plastic mixers, plastic mixers, kneaders, plasticizers, plastic granulators, plastic recycling granulators, plastic pelletizers, screening machines, crushers, plastic injection molding machines, plastic extrusion Molding Machine, Plastic Blow Molding Machine, Plastic Roll Forming Machine, Pressing Machine, Extruding Machine, Blow Molding Machine, Rotation Molding Machine, Foaming Machine, Plastic Thermoforming Machine, Plastic Welding Machine, Plastic Heat Sealing Machine, Plastic Hot Stamping Machine , plastic vacuum evaporation machine, plastic pipe expanding machine, plastic profile assembly machine, plastic scrap automatic recycling machine, automatic injection molding machine, injection mold cooling machine. important Safeguarding load Plastic extruder, workshop equipment lighting, fire pump facilities important II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability 1. The users of plastic products industry are generally 24 hours continuous production, which belongs to continuous load and is basically not affected by time, season and climate. 2. The emergency peak load shifting and power cutoff can disable the non-productive load and some auxiliary production equipment loads, and will quickly respond to peak load shifts. The industry has a moderate electricity load, and the effect of emergency peak load limiting is generally low. 3. Phase-shifting peaks, users of the industry can effectively carry out the production of power transmission by suspending production of part of the production line, and the phase-shifting peak effect is better. 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, a production line (plastic extruder, high-speed mixer, slitter, etc.) can be selectively released for a period of time in combination with its own production process. ) 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 auxiliary production loads, and then 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 is possible to selectively release several pieces (plastic extruders, high-speed mixers, slitters, etc.) in combination with its own production process for a period of time. ) Production lines and other production loads. Use half of the production method to limit electricity or perform a twenty-day stop for ten days each month. 2. Emergency peak shift Based on the implementation of the IV-grade scheme, under the premise of executing the peak-shifting instructions and completing the peak-displacement index, while retaining the basic security load, it is also possible to selectively disable high-speed mixers, slitters and other components in combination with its own production process. Productive load. (III) Level II Participation Scheme for Gap 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, several production lines (plastic extruders, high-speed mixers, and slitters) can be released selectively in combination with their own production process. Etc) and other production loads. Use half of the production method to limit electricity or perform a fifteen-day suspension for fifteen days each month. 2. Emergency peak shift Based on the implementation of the Level III program, under the premise of executing the peak shifting instructions and completing the peak shifting factor, while retaining the basic security load, it is also possible to selectively disable high-speed mixers, slitters and other components in combination with its own production process. Productive load. (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, it can selectively release all of it within a period of time in combination with its own production process (plastic extruders, high-speed mixers, slitters, etc.) Production line 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 instructions and completing the peak shifting factor, while retaining the basic security load, the high-speed mixer and the cutting machine can be selectively deactivated in combination with its own production process. Productive load. Fourth, the industry users involved in the peak load shifting risk and precautions 1. The users of the plastics industry are continuous production equipment. Sudden loss of power will result in greater economic losses and damage to the equipment. The production line must be 2 hours ahead of schedule to safely stop production. Once the production line is shut down from production to normal operation, it takes 2 to 1 3 days to ensure product quality meets standard requirements. 2. The production equipment load of the plastics industry accounts for only a small percentage of the production load, which is about 20%, and it cannot be shut down for a long time. Otherwise, the raw materials will not be fully supplied and will eventually stop production of all production lines. 3. It is not appropriate for the plastics industry to participate in the peak shift and it is not appropriate to adopt compulsory pull-in or remote control equipment to control power cuts. It is necessary to make arrangements in advance and implement peak-to-peak power cuts in a planned manner. 4. The plastics industry is not suitable for performing weekly breaks in weekly units. This can easily lead to frequent production line shutdowns and unqualified product quality. It is recommended to implement monthly breaks in units of months. In summary, it is not appropriate for the industry to participate in the peak load shift and it is not appropriate to adopt compulsory pull control or remote control equipment to control power cuts. Enterprises should formulate effective internal emergency plans, actively cooperate with peaks and power cuts, and prevent malignant accidents from happening, taking the initiative to shoulder social responsibilities and reducing losses. To the lowest. V. Functions and Applications of Intelligent Power Monitoring 5.1 Project Overview Husky Injection Molding Systems (Shanghai) Co., Ltd. is invested and established by the Husky Group, a famous Canadian machinery manufacturing company. It is located in Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai. It is a leading supplier of injection molding equipment and services for the plastic industry, designing and manufacturing. The most comprehensive range of injection molding equipment in the industry, including machines, molds, hot runners and robots. The original power distribution system is only equipped with the power meter of the power department on the total line of the whole plant. The manager can only know the total amount of electricity provided by the power department in each month. Wherever there is, whether there is wasted energy, and whether the energy-saving measures have had a corresponding effect, business managers are not very clear and urgently need a reasonable electric energy assessment mechanism to realize the scientific management of electric energy. In response to the above problems, and according to customer requirements, the existing distribution system was modified. The modified Acrel-3000 energy management system can not only achieve remote monitoring and centralized management of each distribution circuit, but also realizes classified energy statistics. Multi-rate energy statistics, daily energy consumption statistics and monthly energy statistics, and maximum demand alarms provide scientific basis for energy conservation management. 5.2 User Requirements The customer requested that a total of 40 circuits to be reformed in Husky Injection Molding Systems (Shanghai) Co., Ltd. be designed and modified to realize the measurement display of the power parameters of the transformed circuit and the energy metering, and the current limit alarm (three-layer red on site). Yellow and green lights show). Acrel-3000 power management system is used to achieve real-time monitoring and classification of remote electric parameters (current, voltage, power, power factor, etc.). The maximum demand (MD) measured in the field is compared with the preset limit of the system, and the alarm is given when the quantity exceeds the limit. 5.3 Acrel-3000 Design Solution figure 1 The specific application topology on this project; Acrel-3000 transmission and distribution monitoring system is mainly divided into three layers: station management layer (IPC, printer, UPS power supply), communication management layer (4-port communication management machine), on-site Device layer (field smart device). As shown in the above figure, the communication cable of the IO device in the site is RVSP 2*1.5 shielded twisted pair and connected to the 4-port communication manager. (1) Field device layer According to the requirements of Husky's injection molding site, the smart meter must meet the requirements for all-electric parameter acquisition (three-phase current, voltage, active power, reactive power, power factor, frequency, power, switch, etc.); according to customer requirements, The ACR220EL/K multifunction instrument was selected for its site, fully meeting the requirements of the site. ACR220EL is a LCD screen display that can monitor three-phase current, three-phase voltage, power grid frequency, three-phase (active power, reactive power, power factor), three-phase active energy, three-phase reactive energy 6 parameters. In addition to the above functions, other functions can be selected. The following three functions can be selected together or several of them can be selected: F (multi-rate energy statistics), D (maximum demand), and CP (Profibus-DP). Only one of the following three functions can be selected: M (analog), K (2DI/2DO). (2) Station Control Management Configured as EVOC IPC-810B Core2 2.66G / 2G / 500G + keyboard + speakers and so on. Shenzhen Yanxiang Industrial Computer (IPC810B) completed the management of computer monitoring system, database management, on-line and off-line calculation, operation monitoring and control, generation of graph curves, data reporting and other system monitoring functions for the entire power station. Computer main configuration: CPU: PIV 3.0 Memory: 2G Hard Disk: Monitoring Workstation 500G Display: Samsung 19-inch widescreen LCD display Interface: 1000M Ethernet, RS232 interface, LPT port, BNC video output interface, 4 PCI, 2 USB ports, sound card, 14-slot industrial-grade backplane, etc. DVD/VCD drive recorder 4U standard rack-mount chassis Edifier speaker set (for sound alarm) The computer is an industrial computer, designed with a large amount of air flow fan, opened door pullable removable filter, reliable heat dissipation, easy maintenance, and special anti-seismic measures to ensure the normal operation of the machine in harsh industrial environments; UPS power supply for C1KS/1KVA standby 30 minutes tower The monitoring host uses genuine Simplified Chinese Windows XP operating system software, and the energy management software uses Acrel-3000 type energy management configuration software. 5.4 System Functions (1) User Rights Management For different levels of users, set different permissions to facilitate the management of different permissions on the system's different operations to achieve the security and reliable operation of the distribution system. Through user management, users can log in, log out users, change passwords, and add and delete operations. This facilitates the user's modification of accounts and permissions. (2) System main interface The system provides simple, easy to use, and good user interface. Using Chinese interface, CAD graphic shows the primary electrical wiring diagram of the electrical distribution system, shows the status of the electrical distribution system equipment and the corresponding real-time operating parameters, the screen timing switching tour; dynamic refresh of the screen real-time; analog display; switch display; continuous recording The display, etc., can be seen by the changes in the screen colors (red indicates the closing state and green indicates the opening state). Log in as an ordinary user, and through the operation of the main interface, you can view the electrical parameters (current, voltage, active, reactive, power factor, and power) of each loop. If you log in to the highest authority user, you can realize the internal power report and current of the system. Curve, alarm information printing and exporting function. (3) System remote signaling alarm image 3 Figure 4 When an operating fault occurs in the system, an audible and visual alarm will be promptly issued to prompt the user to respond to the fault circuit in a timely manner. At the same time, the time and loop name of the event are recorded automatically so that the user can query and remember the cause of the fault. (4) Trend curve analysis Figure 5 Acrel-3000 power management system provides analysis interface of real-time curve and historical trend curve, and analyzes the current load running status of the circuit by calling the relevant circuit real-time curve interface. For example, by calling a real-time curve of a dispense loop The signal fluctuations caused by the electrical equipment of the circuit can be analyzed. The historical trend of the system is that the system can view its historical trend for all stored data and facilitate the quality analysis of the monitored distribution network by the engineering personnel. (5) Report statistics Figure 6 Figure 7 The Husky Injection Molding System divides the power report into three types, namely time report, daily report, and monthly report. Select the date to be queried to display the power consumption for each time period, display the report comparison histogram for electricity consumption in each time period, facilitate the administrator to view the analysis (the daily report and the monthly report also have a histogram analysis function), and the system The collected active power data, in accordance with the different names of the loop, automatically generates reports and has a report printing function. It can query and print the power consumption in a certain period of a loop. These reports support Excel export function. . (6) Electric energy pie chart Figure 8 You can view the percentage of electrical energy in different loops at any time to facilitate the adjustment of the company's internal energy consumption. 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 172 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] Plastic products industry peak power limit technical guidance. 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 Pure metal powder for thermal spray refers to a fine powder made from a single metal, such as aluminum, nickel, or titanium, that is used in thermal spray processes. Thermal spray is a coating technique where the metal powder is heated and propelled onto a substrate to create a protective or decorative coating. The pure metal powder is typically chosen based on the desired properties of the coating, such as corrosion resistance, wear resistance, or thermal conductivity. It is important to use pure metal powder to ensure the coating has the desired composition and performance characteristics. 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