Application of Power Demand Side Management and Intelligent Power Monitoring Technology in Peak Dislocation and Limited Power in Textile Industry

I. Analysis of power consumption characteristics of industry users

According to the national production industry, the textile industry can be subdivided into cotton, chemical fiber textiles and dyeing and finishing, wool textiles and dyeing and finishing, hemp textiles, silk and silk spinning and finishing, manufacturing of textile products, knitwear and knitwear, and Product manufacturing.

The textile industry generally has a large capacity, and most of them use high-voltage power supply and set up dedicated change (equipment) power stations. The users of this industry are basically 24 hours a day, 24 hours a day, and the average power load is relatively even. The production load accounts for about 95% of the total load. The office load (including living lighting) load accounts for about 5% of the total load.

Spinning main production process: cotton cleaning process (open cotton - cotton - mixed cotton - into a roll), carding process (carding - impurity removal - mixing - into strips), the process of the roll (coiling and drafting - Rolling), combing (composting - carding - drafting - striping), drawing (parallel-drafting-blending - striping), roving (drafting-twisting), spinning (drawing) Stretch-Twisting-Rolling-Molding, Winding Processes (Rolling and Forming-Dedestration), Twisting Processes (Twisting-Winding-Molding), Shaving Processes, and Packing Processes.

The main production process of weaving: the warping process, sizing grouping, threading process, weaving process, and finishing process.

Textile industry user equipment classification

category

Major equipment

Note

Non-productive load

Office lighting, office air conditioners, office equipment (computers, etc.), dormitory lighting, dormitory air conditioners, cafeteria lighting, canteen air conditioning, canteen electrical equipment (steamed rice cookers, ovens, freezers, etc.).

general

Auxiliary production load

Workshop lighting, workshop air conditioning, ventilation equipment, workshop humidifiers, etc.

general

The main productive load

Power Equipment (Cryogenic Nitrogen Generators, Freezers, Air Compressors, Fans, Water Pumps, Steam Boilers, etc.), Front Spinning Equipment (Cleaning Machines, Pre-carding Machines, Carding Machines, Roving Frames, Draw Frames, Precision (comb), after-spinning equipment (spinning machine, automatic winder), weaving equipment (spinning machine, twisting machine, cloth machine, trademark loom, roll cloth machine, cloth inspection machine, ribbon machine, woven fabrics Machines, water jet looms, air jet looms, warping machines, sizing machines, weft winders, trimming machines, circular weft machines, flat knitting machines, denim shrinking machines, water jet looms, air jet looms, films Weaving machines, shuttle looms, weft winding machines, circular looms, shuttle looms, weaving machines (warp knitting machines, crochet machines, knitting machines, glove machines, socks machines, carpet looms, jacquard weaving machines) , towel looms), other equipment (washing machine, rope making machine, slotting machine, needle combing machine, mixing machine, slivering machine, feeding machine, winder, hemp spinning machine, weft feeder, jacquard machine , loom looms, creel stands, rapier looms, sizing machines, warping machines, coiling machines, cloth inspection machines, webbing machines, filament doublers, filament processing machines, winder machines, Yarn staple fiber post-processing equipment, viscose staple fiber post-processing production, spinneret, spinning pump, winder, drafting machine, winder, crimper, spinning machine, texturing machine, staple fiber production line, length Silk processing equipment, filament spinning equipment, polymerization equipment, etc.).

general

Safeguarding load

Firefighting system (automatic fire sprinkler system, blower, etc.)

important

II. Analysis of Industry Users' Participation in Peak Dislocation and Power Limiting Capability

1. The industry generally produces continuous production for 24 hours. The average electricity load is relatively stable. The load curve is relatively stable and the loading rate is as high as 95%.

2. The industry is a labor-intensive industry with no significant load. Generally there are multiple production lines, and it is moderately capable of participating in emergency peak excursions. It is more suitable for participating in phase-shifting and peak-reduction power cuts.

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

(I) Gap Level IV Participation Plan

Phase-change peak

1) First, advocate users to save electricity:

A. Turn off the lights in hallways, passages, bathrooms and other places where natural lighting is better.

B. The lighting in the office shall be on and off; the air conditioning shall be turned on when the room temperature is higher than 30Â°C, and the air-conditioning temperature shall not be set below 28Â°C.

C. Reduce the standby time of office equipment: office equipment mainly includes computers, printers, fax machines, copiers, and drinking fountains. After the work is completed, all electrical equipment in the office shall be closed in time to prevent the office electrical equipment from being in the standby state.

D. Turn off landscape lighting.

2) Reduce or deactivate production loads such as flower cleaning machines, pre-carding machines, carding machines, roving machines, draw frames, and combing machines.

2. Emergency peak shift

During the period from 8:00 to 22:00, non-productive loads such as lighting, office air conditioning, and office loads are reduced; non-productive loads such as lighting, office air conditioning, office load, and landscape lighting are suspended from 18:00 to 22:00.

Reduce or deactivate production loads such as flower cleaning machines, pre-carding machines, carding machines, roving frames, drawing frames, and combing machines.

(II) Gap Level III Participation Plan

Phase-change peak

On the basis of implementing the IV-grade plan, reduce or disable auxiliary production loads such as workshop lighting, workshop air-conditioning, ventilation equipment, and workshop humidifiers; reduce or disable flower cleaning machines, pre-carding machines, carding machines, roving machines, and Machines, combers, and other productive loads.

2. Emergency peak shift

On the basis of implementing the IV-grade plan, reduce or disable auxiliary production loads such as workshop lighting, workshop air-conditioning, ventilation equipment, and workshop humidifiers; reduce or disable the cleaning machines, pre-carding machines, carding machines, roving machines, and Machines, combers, and other productive loads.

(III) Level II Participation Scheme for Gap

Phase-change peak

On the basis of the implementation of the Grade III program, the power equipment load and other production loads of cryogenic nitrogen generators, freezers, air compressors, fans, water pumps, steam boilers, etc., will be reduced or deactivated.

2. Emergency peak shift

(IV) Gap Level I Participation Plan

Phase-change peak

All auxiliary production and production loads are deactivated.

2. Emergency peak shift

All auxiliary production and production loads are deactivated.

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

The textile industry is a labor-intensive industry with no significant load. There is basically no security risk involved in peak load shifts and power cuts, and companies can do a reasonable job of dispatching workers. The peak load limitation power needs to retain about 10% of its total capacity to ensure the electricity demand of the fire fighting system (automatic fire sprinkler system, air blower, etc.) and dormitory living electricity.

Therefore, when the users of the industry participate in the peak shift, the enterprises should scientifically and reasonably prepare internal emergency plans according to their own actual conditions, actively cooperate with the peak implementation, eliminate accidents, take initiative to undertake social responsibilities and minimize losses.

V. Functions and Applications of Intelligent Power Monitoring

5.1 Project Overview

Changshu Polyester Co., Ltd. (formerly Changshu Polyester Factory) is a professional manufacturer of high-strength low-stretch polyester filament yarn and FDY high-strength low-shrinkage polyester industrial yarn (fine denier), and has the right to self-import and export. Founded in 1983, the company is located in Xuzhou, Donggu Town, Changshu City in the Yangtze River Delta. The plant covers an area of â€‹â€‹49,900 square meters and a building area of â€‹â€‹27,319 square meters. There are four production plants. Due to the relatively large electricity consumption of Changshu Dacron Plant, and in response to a series of policies and measures to promote energy-saving and emission reduction formulated by the State Council, it is better to monitor and manage the distribution system. Therefore, a background power monitoring and power management system was established to intelligently manage power distribution.

The plant's power distribution system is mainly controlled by the high voltage motor outlet on the first floor of the factory and the power distribution room on the third floor. A total of high pressure outlet loops, 32 low voltage outlet loops, high pressure outlet loops, and the entire third floor power distribution room provide the whole The power needed for the production of Changshu Dacron. The monitoring duty room is set up in the factory's second floor monitoring room.

5.2 System Structure

Acrel-3000 power management system provides basic platform for real-time data acquisition, on-off status monitoring, and remote management and control of large-scale public buildings using monitoring host, communication equipment, and measurement and control unit as basic tools. It can be configured with detection and control equipment. Complex monitoring system. The system mainly adopts a hierarchical distributed computer network structure, as shown in the figure below: station control management layer, network communication layer and field device layer.

1) Station control management

Station management The management personnel of the power management system are the direct windows of human-computer interaction and the top part of the system. Mainly by the system software and necessary hardware equipment, such as industrial-grade computers, printers, UPS power supply and other components. The monitoring system software has a good human-computer interaction interface, calculates, analyzes, and processes various types of data collected on the site, and reflects the operating status of the site with graphics, digital display, and sound.

Monitoring host: used for data acquisition, processing and data forwarding. Provides data interfaces within or outside the system for system management, maintenance, and analysis.

Printer: The system calls for printing or prints graphics, reports, etc. automatically.

UPS: Ensures the normal power supply of the computer monitoring system. When power supply problems occur in the entire system, ensure the normal operation of the station control management equipment and provide sufficient time for data storage.

2) Network communication layer

The communication layer device is a CP134U-I expansion card. This layer is a bridge for data information exchange. It is responsible for the collection, classification, and transmission of data information sent back by field devices, and it also conveys various control commands from the upper computer to the field devices.

Communication medium: The system mainly adopts shielded twisted pair, uses RS485 interface and MODBUS communication protocol to realize real-time communication between field device and host computer.

3) Field device layer

The field device layer is a data acquisition terminal, which is mainly composed of smart meters. It adopts a distributed I/O controller with high reliability and a field bus connection to form a data collection terminal, and uploads the collected data to the data center. The measuring instruments are responsible for the most basic data collection tasks. The data they monitor must be complete, accurate and transmitted to the monitoring host in real time.

5.3 System Functions

The upper computer software is Acrel-3000 energy management system configuration software, which is dedicated software for the collection and monitoring of on-site electrical parameter data, the biggest feature is that it can be carried out in a flexible and diverse "configuration" rather than programming System integration, it provides a good user development interface and a simple method of engineering implementation, as long as its pre-configured various software modules for a simple "configuration", it can be very easy to achieve and complete the collection of on-site data Monitoring function. Acrel-3000 energy management system has a friendly human-machine interface, which can collect real-time and time-sequenced parameters of each field device's electrical parameters and switch status, and upload the collected data to the monitoring host for real-time display and storage. The system also provides analysis of real-time curves and historical trend curves, and meets the functions of reports, event records, and fault alarms required by the user. The entire system can realize the collection and statistics of all circuit power consumptions, and realize remote automatic meter reading, power monitoring and power management functions.

1 Data Acquisition and Display

The field instrument measures and collects the loop data information. The PC software then collects and stores the data of the field instrument at regular or periodic intervals. The collected time period can be freely set and the minimum system supports the acquisition period. You can view any meter's instantaneous table value, accumulated amount, and other information at any time, and record the voltage, current, power factor, and active power of the power meter within the time interval. These parameter information can be automatically saved to the database for easy querying.

The system has a friendly man-machine interface, which is convenient for ordinary on-site personnel to view and record relevant information. The system one-time diagram not only shows the on/off status of the line, but also displays important power parameters such as voltage, power, and active power in real time. All data information is regularly saved to the database.

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 Ã— 120mm, opening size: 108 Ã— 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 Ã— 89 Ã— 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 Ã— 89 Ã— 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

Power Meter

Network Power Meter

ACR330ELH

only

Ankerui

Network Power Meter

ACR220EL

only

Ankerui

Monitoring Center duty room

Console

YT-341

set

Xianghe

Workstation host

IPC-610L/769VG/E5300/2G/500G/DVD/88 Mini Key+Mouse (Original Machine Standard) 2 Serial Ports

station

Advantech

monitor

L197WA

station

Lenovo

UPS power supply

C1K/1KVA

station

SANTAK

printer

HP 1108 A4 format

station

HP A

system software

Genuine Microsoft WINDOWS XP/SP3

set

Microsoft A

Industrial network switch

D-LINK 16 ports

station

D-LINK

Industrial Serial Server

NPORT5232I RS485 interface Ã— 2 with light isolation

station

MOXA

Industrial switching power supply

KDYA-DG30-24K

only

Huali

Power Management Software

System Configuration Software Acrel-3000V6

set

Ankerui

Power Management Software

Data Storage Software Acrel-dbSQL

set

Ankerui

Power Management Software

Energy Management Software Acrel-EnerSys

set

Ankerui

Power Management Software

Device Driver Software Acrel-Driver

set

Ankerui

Photoelectric converter

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

only

Engineering Materials

Communication cable

Single-mode 4-core fiber

Communication cable

Shielded twisted pair RVVSP 2*0.75

0.2

Sail

Communication cable

BVR 1.5mm

Engineering materials

Towboards, conversion lines, lines, signs, etc.

set

Measuring box

A total of 4 units are required to be installed in each substation.

only

Fiber Optic Accessories

Includes welding, pigtails, flanges, jumpers, etc.

set

Construction and commissioning

Communication cable laying

Meter

2200

Comprehensive debugging

People/day

Equipment transportation costs

item

training fees

item

Construction renovation costs

item

references:

[1] Ankerui Electric Co., Ltd. System Solution, 2013.1.

[2] The peak load shifting technical guidance for the textile industry.

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