Application of Ankerui Energy Efficiency Management System in Anhui Jinsheng Chemical Industry

Xu Shuang

Ankerui Electric Co., Ltd., Jiading 201801, Shanghai, China;

Abstract: Introducing Ankerui energy efficiency management system, adopting intelligent power meter to collect various electrical parameters of 35KV power distribution site. The system adopts the on-site local networking method. After the networking, it is remotely transmitted to the monitoring background through fieldbus communication, and the real-time monitoring, analysis and management of power distribution circuit substations in the substation are realized through the energy efficiency management system.

Keywords: substation; intelligent power meter; energy efficiency management system;
Overview

Anhui Jinyu Chemical Co., Ltd. was completed and put into production in 1975. At that time, ammonia production was only 3,000 tons. After years of continuous transformation, it has now become an annual output of 100,000 tons of synthetic ammonia, 100,000 tons of urea, and 60,000 tons of ammonium bicarbonate. 20,000 tons of methanol, 50,000 tons of formaldehyde, 50,000 tons of compound fertilizer, 500 tons of flavors and fragrances of comprehensive chemical companies. The company covers an area of ​​150,000 square meters, with total assets of 160 million yuan and 1080 employees.

The plant mainly has 1 line of 35KV incoming line, 6-way straight-change (35KV/6.3KV), 6-way straight-change (35KV/0.4KV) and several 0.4KV feeder circuits.

The company's annual input costs in terms of electricity consumption are relatively large. It is mainly unclear about the quality of electricity used and the details of electricity consumption. It creates a lot of confusion for power management personnel and puts forward the following requirements according to their actual conditions:

According to the needs of users, the 35KV substation of Anhui Jinyu Chemical Co., Ltd. needs to be reconstructed and an energy efficiency management system (mainly real-time data monitoring and energy data processing and analysis) will be established. A monitoring platform will be set up on the 35KV next door duty room for the reformed Real-time monitoring, statistics and analysis of loops to ensure the safety, reliability and efficiency of electricity use.

Ankerui energy efficiency management system makes full use of the latest developments in modern electronic technology, computer technology, network technology and field bus technology, and conducts distributed data collection and centralized monitoring and management of the power distribution system. The secondary equipment of the distribution system is networked. Through the computer and the communication network, the field devices of the decentralized power distribution station are connected into an organic whole, and the remote monitoring, centralized management and energy efficiency analysis of the power grid operation are realized.

Customer Demand Due to the relatively strict time limit for power cuts by factories, this reformation is mainly aimed at 35KV substation main transformers and direct-transformation loops. The number of 0.4KV loops is relatively large, and subsequent reforms will be carried out successively. When the main transformer and the linear transformer current exceed the limit, they cannot be known by the management personnel in real time. The hidden danger of the safe use of electricity is that the system needs to be able to implement the SMS notification function. 35KV outlet circuit is a pointer meter, relying on manual periodic meter reading, can not count the specific electricity consumption every moment. Without monitoring the power factor of each outlet circuit of 35KV, when the power factor of the incoming circuit is relatively low, it is impossible to carry out investigations, and often a fine will be received from the power supply bureau. The new meter needs to have a power factor measurement function. The factory's workers are three teams, manual meter reading can not be accurate to the specific electricity consumption of each team, can not really achieve internal performance assessment. Real-time monitoring of real-time changes in current, voltage, power, and energy consumption of the main and linear transformers. Ability to view the daily electricity usage of a particular circuit or circuits, and compare them to form pie charts and bar graphs. Each main change and direct change can see the current day energy consumption, yesterday's energy consumption and the same period of energy consumption. You can manually set the time period for peak, level, and valley energy consumption statistics. The system can achieve year-on-year, ring-to-loop analysis capabilities. The system can be accessed remotely, enabling managers to view the working status of the power circuits of the engineering system at any time.

2 System Structure Description

The monitoring system adopts a hierarchical distributed structure, namely station control layer, communication layer and bay layer; as shown in Figure (1):

Figure (1) Network topology of energy efficiency management system

The main equipment for the interval device is: smart meter, switch quantity, analog acquisition module and frame circuit breaker. 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 main network communication layer is: a communication server. The main function of the communication server is to collect the scattered data at the site collection device, and transmit it to the station control layer at the same time, to complete the data exchange between the field layer and the station control layer.

Station control management: equipped with high-performance industrial computers, monitors, UPS power supply, printers, SMS module, buzzer and other devices. 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.

After the transformation, the additional intelligent power meter adopts RS485 interface and MODBUS-RTU communication protocol. RS485 adopts shielded wire transmission. Generally, two wires are used for connection. The connection is simple and convenient; the communication interface is half-duplex communication and both parties can communicate. Receives and sends data but can only send or receive data at the same time. The maximum data transfer rate is 10 Mbps.

The RS485 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.

3 main functions of energy efficiency management system

3.1 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 Epi, 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.

3.2 Human-computer 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 distribution system, shows the status of the distribution system equipment and the corresponding real-time operating parameters, the screen timing switching tour; dynamic refresh of the screen in real time; analog display; switch display; continuous Record display and so on.

3.3 Diachronic events

The duration event viewing interface provides users with easy and friendly human-computer interaction by viewing the fault records, signal records, operation records, and over-limit recordings that have occurred. You can view the platform through historical events. You can easily locate the fault according to your requirements and query conditions. The historical events that you want to view provide you with good software support for the overall system operation.

3.4 Database Establishment and Query

It mainly completes remote measurement and remote signal acquisition, and establishes a database to generate reports regularly for users to query and print.

3.5 User Rights Management

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. You can use user management to perform user login, user logout, password change, and add/delete operations to facilitate the user's modification of accounts and permissions.

3.6 Running load curve

Load trend curve function is mainly responsible for the timing of important loop current and power load parameters, automatic generation of operating load trend curve, to facilitate users to understand the equipment operating load status. Click the corresponding button or menu item of the screen to complete the switching of the corresponding function; you can view the real-time trend curve or historical trend line; you can perform operations such as pan, zoom, and range conversion on the selected curve to help the user to enter the line trend.

Potential analysis and fault recall provide intuitive and convenient software support for analyzing the operating status of the entire system.

3.7 Remote Report Query

The main function of the report management program is to design the report style according to the needs of the user, and the data processed in the system is filtered, combined and statistically generated to generate the report data required by the user. This program can also be based on the needs of users of the report file to save, print or summon save, print mode. At the same time, this program also provides users with management functions for generated report files.

The report has the functions of freely setting the query time to realize daily, monthly, and annual energy statistics, data export, and report printing.

3.8 System Energy Analysis Function

It can realize the year-on-year and ring-ratio analysis of the energy consumption system, query the peak, flat and valley electrical value according to the customized time period, and can calculate the energy efficiency ratio of a certain team according to the energy consumption of the team.

4 Case Studies

The monitoring system mainly realizes the real-time monitoring, analysis and management of the 35KV substation of Anhui Jinyu Chemicals. The monitoring scope is as follows:

1 line 35KV line, 6 line straight (35KV/6.3KV), 6 line straight (35KV/0.4KV).

Ankerui Electric Co., Ltd. uses a multi-function watt-hour meter for DTSD1352-CF, and the transformer uses the original transformer of the high-voltage cabinet for project modification.

DTSD1352-CF size and detailed parameters:

Features

Function Description

DTSD1352

Energy metering

Active energy metering (positive and negative)

â– 

Reactive energy metering (positive and negative)

â– 

A, B, C phase split positive active energy

â– 

Electricity measurement

U, I

â– 

P, Q, S, PF, F

â– 

LCD display

8-bit LCD display

â– 

Key Programming

4 buttons programmable communication, ratio and other parameters

â– 

Pulse output

Active pulse output, clock pulse output

â– 

Reactive pulse output

â–¡ (multiple with clock)

LED News

Loss of pressure and data validation failure

â– 

Multi-rate and

With functions

Supports 4 time zones, 2 time tables, 8 day time, 4 rates

â– 

Four maximum demands and time

â–¡

Previous December history freeze data

â–¡

Date, time

â–¡

communication

RS485 interface, supports Modbus, DL/T645-07, DL/T645-97

â–¡

According to its modified circuit, the system can display the real-time running status of the primary circuit. The power meter remotely monitors the electrical parameters of the operating equipment, including the three-phase voltage, current, power, power factor, electrical energy, frequency and other electrical parameters. See Figure (2)

Figure (2) Secondary diagram of system power distribution

The telemetering and reporting function mainly completes the report of the position and sound of the direct-change and main-transform load over-limit popup interface, and prompts the on-duty personnel to handle it in time. The load limit can be set freely under the corresponding authority. With historical query function, see Figure (3).

Chart (3) Hedge Report Information

The electricity consumption report function can select the time period to inquire, supports the accumulated electricity inquiry at any time, and has the functions of data export and report printing. Provide accurate and reliable power report for duty personnel. The names of the loops in this report are associated with the database, allowing users to modify the loop names. Users can directly print the reports and save them in EXCEL format to other locations. Figure 4 Main transformer and direct-change energy statistics reports.

Figure (4) Energy Report

Parameter reading function, the main line of all electrical parameters into the line query. Supports electrical parameter query at any time, with functions such as data export and report printing. This report queries the six main transformers and six direct-transformed electrical parameters for 35KV substations, which mainly include: three-phase voltage, three-phase current, active power, reactive power, frequency, and active power. The names of the loops in this report are associated with the database to facilitate the user to modify the loop name, as shown in Figure (5).

Figure (5) Parameter meter reading

Real-time power factor monitoring function, the power factor is too low and the system reports in real time, the user will repair or replace the equipment of the circuit according to the power factor condition. The power factor report is shown in (6).

Figure (6) Power Factor Trend Graph

The team assessment report can be used to calculate the electrical parameters and energy consumption values ​​of the working period of each team in real time, as shown in Figure (7).

Figure (6) Team report

The load trend curve interface allows you to visually check the load operation of the loop. View real-time and historical trend curves, click the corresponding button or menu item to complete the switching of corresponding functions; help the user to enter the trend analysis and fault recall, with curve printing function. Provides intuitive and convenient software support for analyzing the overall system health, see (7)(8)(9)(10).

Graph (7) current trend graph

Figure (8) voltage trend graph

Figure (9) active power trend graph

Figure (10) active power trend graph

Year-on-year and ring-to-turn analysis, as shown in Figure (11)

Graph (11) year-on-year analysis

The comparison of energy consumption on the day, yesterday's energy consumption and energy consumption during the same period is shown in Figure (12).

Figure (12) Comparison of Energy Consumption

Peak, level, valley energy analysis, as shown in Figure (13).

Figure (13) Peak, Plane and Valley Energy Consumption Analysis

The monthly power consumption, power consumption, and total line power trend analysis are shown in Figure (14).

Figure (14) Main Screen of Energy Efficiency Management

The system can set different permission groups for users of different levels to prevent the loss caused by human misoperation to production and life, and realize the safe and reliable operation of the distribution system. You can use user management to perform user login, user logout, password change, and add/delete operations to facilitate the user's modification of accounts and permissions.

System Configuration:

No.

name

Model, specification

unit

Quantity

Note

1

Power Meter

Network Power Meter

DTSD1352-CF

only

12

Ankerui

total

12

2

Monitoring Center duty room

Communication cabinet

K2200 (2200*600*600)

set

1

Console

custom made

set

1

Workstation host

IPC-610MB (Core2 Q8400/4G/1TB/DVD/Discrete Graphics Card) + Keyboard

station

1

Advantech

Workstation host

RPC-610 E5800 3.2GHz/2G/500G+ Keyboard

station

1

North China Industrial Control

monitor

L197WA

station

2

Lenovo

UPS power supply

C1K/1KVA

station

1

SANTAK

printer

HP 1106 A4 format

station

1

HP

system software

Genuine Microsoft WINDOWS XP/SP3

set

1

Microsoft Party-owned

system software

Standard Edition WINDOWS 2003 SERVER

set

1

database

SQL Database (Standard Edition)

set

1

Energy efficiency management

Acrel-5000 Energy Management Software

set

1

Ankerui

Energy efficiency management

Data remote receiving service software

set

1

Ankerui

Energy efficiency management

Reporting Services Software

set

1

Ankerui

Energy efficiency management

Middle-tier server C/S server (configuration, debugging)

set

1

Ankerui

Energy efficiency management

Middle tier server B/S server

set

1

Ankerui

Energy efficiency management

Software implementation/debugging fee

item

1

Communication collection box

600*550*300

set

2

Shanghai Xiangming

Industrial Serial Server

NPORT5630-8 RS485 interface × 8

station

1

MOXA

Industrial Serial Server

NPORT5430I RS485 interface ×4 with light compartment

station

2

MOXA

Industrial switching power supply

KDYA-DG75-24

set

2

Huali

Photoelectric converter

Single mode photoelectric conversion HTB-1100S(25km)

only

4

Zhao Yue

total

3

Engineering Materials

Communication cable

Shielded twisted pair RVVSP 2×1.0

km

1.5

Communication cable

Single-mode 4-core fiber

km

1

Fiber Optic Accessories

Includes welding, pigtails, flanges, jumpers, etc.

set

4

Engineering materials

Towboards, conversion lines, lines, signs, etc.

set

1

Note: The quotation list reserves 2 communication collection boxes for 6.3 substations, which is convenient for users to incorporate the system after the later transformation.

After the investment of the entire system, according to the follow-up management of energy-saving and energy-saving equipment, the company can save costs of 300,000 yuan per year.

4 Conclusion

The energy efficiency management system can collect real-time energy consumption data of the entire company in the production process in real time, monitor all data online, and report data with abnormal power consumption during the process. It can also provide data analysis and comparison functions in the form of charts or data tables for the energy consumption information in the process, through horizontal comparisons between equipment and equipment, between teams and teams, or between weeks and weeks and between months and months. Compare and identify the waste and hidden dangers in the process of energy consumption. Through the design of various statistical reports to the user to establish an enterprise energy consumption equipment assessment system and production team energy assessment management system to optimize the energy consumption of enterprises, so that employees from the past passive energy saving to active energy saving ideological changes, to improve business performance Consumption efficiency, lower production costs, and improved economic efficiency.

references:

[1]. Ren Cheng, Zhou Zhongzhong. Principles and Application Guide for Digital Meters for Electric Power Measurement [M]. Beijing. China Electric Power Press, 2007. 4

[2].Zhou Zhouzhong, et al. Product Selection and Solution for Smart Grid User-end Power Monitoring and Power Management System[M]. Beijing. Machinery Industry Press. 2011.10

About the Author:

Xu Shuang, female, undergraduate, Ankerui Electric Co., Ltd., the main research direction for the smart grid power distribution, Email: Mobile QQ

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