I. Analysis of power consumption characteristics of users in the industry Cement manufacturing belongs to the cement, lime and gypsum manufacturing under the non-metallic minerals manufacturing industry directory and belongs to the heavy industry. It refers to the addition of appropriate amounts of gypsum or certain mixed materials with cement clinker, followed by grinding equipment (concrete grinding) to a specified fineness. Made of hydraulic cement production activities. The industry is increasingly large-scale production, its production process is very universal, nothing more than ore mining, transmission ~ ore crushing ~ rotary rotary kiln firing ~ clinker grinding ~ finished package, the nature of the production of three shifts continuous operation. The industry generally has 110kV or 220kV substation (with security power supply) power supply, and some residual heat self-generating power plants, substations for the pressure after the drop for each branch. Its power load is relatively large, generally around 80,000 kilowatts or even greater; the production nature is generally three-shift continuous operation. Cement industry user equipment classification category Major equipment Note Non-productive load Office lighting, computer fax printing and other office appliances, split and central air conditioning, cafeteria rice cookers, blowers, plant road lighting general Auxiliary production load Transmission fan, conveyor motor, hoist, air compressor, pulverizer general The main productive load Raw material mill, cement mill, rotary kiln important Safeguarding load Cooling water pump, lubricant pump, auxiliary rotary kiln, transmission equipment important II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability 1. The industry has a large electricity load and a continuous load, regardless of time, season or climate. 2. The industry's emergency peak load shifting can quickly disable the consumption of high-power electrical equipment such as cement mills and raw material mills. The emergency peak excursion capacity is strong, but the load of the kiln can not participate in the emergency peak load reduction. 3. The phase shift of users in this industry can be carried out by arranging for centralized inspections and production cuts. If centralized maintenance is adopted, only the maintenance of kiln load and some maintenance lighting equipment such as living lights can be reserved. The maintenance is generally about 1000 kW. The load can be used; if the production method is adopted, the production line can be stopped gradually to reduce the production load and achieve the peak load shifting effect. Third, the industry users involved in the peak load limitation technology program (I) Gap Level IV Participation Plan 1. Staged peak shift: When executing the peak-shifting instructions, some cement mills are given priority in arranging for participation in the peak shift. Under the premise of completing the peak-displacement index, 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 instructions, it is necessary to quickly invest in the limited load, prioritize the air-conditioning lighting equipment, and when it is unable to meet the requirements, arrange part of the cement mills to participate in the peak load, and then gradually release the load according to the instructions to resume normal production. (II) Gap Level III Participation Plan 1. Staged peak shift: On the premise of ensuring safety, all cement mills and some raw mills participated in the peak shift in the peak load shift period on the basis of the implementation of the IV-grade plan. Under the premise of completing the peak-displacement index, combined with its own production process flow, it can selectively release part of the equipment load at different time periods. 2. Emergency peak shift 1) 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. 2) On the basis of the implementation of the IV-grade plan, after receiving the peak load command, it is necessary to quickly put all the cement mill load limit, and then gradually release the load according to the instructions to resume normal production. (III) Level II Participation Scheme for Gap 1. Staged peak shift: 1) On the premise of ensuring safety, based on the implementation of the Grade III program, all cement mills, raw material mills, and mine long-distance transmission belt transmission systems participate in the peak load shift during the peak load shifting period. Under the premise of completing the peak-displacement index, combined with its own production process flow, it can selectively release part of the equipment load at different time periods. 2) For the equipment with long response time in the mine long-distance transmission belt transmission system, it is necessary to make preparations for peak dislocation in advance and ensure that all the limited load can participate in the peak shift at full time. 2. Emergency peak shift 1) 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. 2) On the basis of the implementation of the Grade III program, after receiving the peak shift instruction, all cement mills and raw material mills will be quickly put into service. If necessary, the main power equipment of the rotary kilns will be shut down and the auxiliary transmission equipment will be used to achieve the purpose of limiting load. Then gradually release the load according to the instruction to resume normal production. (IV) Gap Level I Participation Plan 1. Staged peak shift: 1) Taking into account the large power gap, companies can arrange for overhaul of the entire plant, leaving only the power load required to repair the equipment. 2) During the peak load shifting period, firstly put in load-limiting equipment such as cement mills, raw material mills and rotary power plants with high load limits and fast response time; and gradually invest in long-distance transmission in mines with slow response time. With the transmission system to ensure that all limitable loads all participate in the peak shift. 2. Emergency peak shift On the basis of the implementation of the Level II program, after receiving the peak shift instruction, it is necessary to rapidly input cement mills, raw material mills, and main power equipment such as rotary kilns to limit the load, and then gradually release the load according to the instructions to resume normal production. Fourth, the industry users involved in the peak load shifting risk and precautions 1. Disable clinker and raw material grinding system risks and precautions Must be prepared in advance, wait until all the material is exhausted before it can be stopped, otherwise it will cause the hoist to be unable to start under heavy load condition, or be blocked by the powder in the transmission chute, which will cause the system to be unable to transmit powder for a long time after the power is turned on again. material. Preparation usually takes 10 minutes. 2. Mine long-distance transmission belt transmission system It must be prepared in advance. After all the mineral materials on the conveyor are drained, they can be shut down. Otherwise, it will not be able to start up again if the conveyor belt is overloaded. The preparation time is determined by the transmission distance, generally not less than 30 minutes. 3. Rotary rotary kiln can not be stopped urgently. The rotary kiln auxiliary transmission device should be enabled within 10 minutes after the main power equipment stops. Otherwise, as the length of the rotary kiln reaches several tens of meters, in the case of emergency stop, the kiln body will be deformed, the internal refractory bricks will be loosened, and the clinker will block the kiln body after hardening. It takes a long time (72 hours) to empty the material in case of full material. Therefore, it is not appropriate for the industry to participate in the peak 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, take the initiative to cooperate with the wrong peaks, eliminate the occurrence of vicious accidents, and take the initiative to shoulder social responsibilities and minimize losses. The new production line 10kV distribution system wiring for the three-phase four-wire, two-way connection between the parent connection. The total drop distribution system diagram is as follows: 5.2 Demand Analysis The Sinopec Pingxiang Cement Line will perform electricity metering for each circuit of the total downsizing substation in advance, and will decide whether to extend the power management system to each 10kV distribution system in the production line depending on the production line usage. The new line 0.4kV distribution system design will not be implemented. Metering function. The 10kV total drop power distribution room has 27 sets of 10kV switch cabinets, of which 19 circuits need to be metered, while the 5 circuits of the 10kV and 110kV sides of the two main transformers and the 110kV total feeders need to be separately measured. In the future, the three backup circuits may be converted to waste heat for power generation and need to measure the inverse power. The user will make a record of production electricity consumption every two hours. The assessment will be conducted every morning, evening and evening. The early morning hours will be 8:00am~4:00pm, the middle class hours will be 4:00pm~12:00pm, and the night shift will be 0:00am. ~8:00am. The data of the total substation and substation is compared once a week with the power distribution room data of the production line, and compared with the power consumption data provided by the power supply bureau every month, as a basis for assessing the energy consumption of each team. 5.3 System Structure The entire system adopts a set of Acrel-3000 power management system, using a hierarchical distributed structure, namely the field device layer, network management layer, and monitoring management layer, as shown in Figure 1: In this project, the electrical measurement of the substation loops was realized by installing ACR320E series multi-function power meters on the total drop 10kV switchgear. In addition, the Zhuhai Wanlida is used in the Central Control Room on the 2nd floor of the total landing and the switchgear is used to measure the positive active and reactive power on the 110kV line of the new line, the high pressure side and the low pressure side of the 1#2# main transformer. Electricity. In addition, ACR320E series instruments are also installed on the 10kV switchgear of the power distribution room of raw material mills, cement mills, kiln heads, kiln tails, and limestone crushers. The power management system will only conduct the back-office networking of the multi-function meters of the power distribution room and the central control room, that is, the field device layer is composed of all ACR320E series meters in the power distribution room and the central control room. The field instrument adopts shielded twisted pair RVVSP2*1.0 as the transmission medium of RS485 bus. The number of instrumentation devices connected to each 485 bus does not exceed 20, and the total line length does not exceed 100 meters to ensure the stability of the data link. . In this project, 24 meters are divided into 2 routes, that is, 19 meters in the power distribution room and 5 meters in the central control room communicate with the back-end system through a 485 bus. Due to the earlier system being small, the communication management device equipment selected Korenix's 4-port serial port server Jetport5604I, which can simultaneously integrate four RS485 buses and have optical isolation. The serial port server is installed in the network cabinet of the central control room, and is connected with the station control management layer through the Industrial Ethernet TCP/IP protocol. The Ethernet transmission medium is a Super Category 5 STP shielded cable. In this project, industrial network switches have been reserved for future system expansion. The main equipment of station control management is DELL's workstations, Yamatake's 1KVA tower UPS power supply and HP's A4 format printer, operating system software Windows XP SP3, and power management system software Acrel-3000 series products. All the equipments in this project are wired, and the communication network construction is completed before the start of the new line production line. During the trial operation, the system debugging is completed. The power management system was put into operation in December 2011 together with the production line. 5.4 System Functions Data Acquisition and Management The data collection required for distribution mainly through the ACR320E network multi-function instrument, PT, CT and other devices will be on-site operating parameters of all electrical equipment, including: current, voltage, active power, reactive power, power factor, active power, etc. Telemetering information and the state of the circuit breaker, such as the closing and closing state, are collected. The instruments are connected to the intelligent communication server through the 485 bus and connected to the power management host through the Ethernet interface. ACR320E network multi-function instrument adopts RS485 interface and MODBUS-RTU communication protocol. RS485 adopts shielded twisted pair transmission, and the wiring is simple and convenient; The communication interface is half-duplex communication, and the maximum data transmission rate is 10 Mbps. The RS-485 interface is a combination of balanced drivers and differential receivers. It has enhanced noise immunity and allows up to 32 devices to be connected on the bus. The maximum transmission distance is 1.2 km. 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 electricity consumption units, different electricity units in the same period of time for electricity statistics; as a management platform for electricity charges, and the actual occurrence of electricity compared; according to the mobile engine power generation, fuel consumption estimates. Clearly reflect the power consumption structure of all departments of the whole plant, establish benchmarking departments, and compare with the benchmarking department and find that there are links such as power theft, electricity leakage, long lights, and unused devices; assess the energy-saving effects of different energy-saving schemes. It helps to selectively select energy-saving measures, and it can also be used as a measurement system for contract energy management projects; The energy report realizes the time-based query of all energy data, and is divided into five types: minute, hour, day, and month. Energy summary table, all monitoring equipment energy summary, according to the time period query, automatic calculation of electricity consumption for any period of time; Print and export, all reports and interfaces can be printed, or exported in EXCEL, WORD format; image 3 Electricity trend The load trend curve provides the load trend of the circuit in a certain period of time, which facilitates the administrator to master the operation status of the power equipment. Through the analysis of historical data, it can provide scientific electricity consumption estimates for new departments and equipment in the future; Analyze the power consumption of each device in the building and the details of the equipment such as the brand, model, and age of the equipment to assess whether the equipment power is reasonable. Through the analysis of the power consumption of the various departments within the building compared with the year-on-year and ring-to-quarter ratio, the equipment is used. Whether electricity is reasonable; After a certain period of time is spent on an energy-saving device or technology, whether the energy efficiency of the evaluation is consistent with the original forecast. The trend of electricity consumption is shown in Figure 4: 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 Three-phase rail mounted energy meter DTSD1352-C only 68 Ankerui Open type current transformer AKH-0.66/K only 192 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] Cement industry's peak power limit technical guidance. Garlic Jelly And Ginger Tube Packaging
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