Application of Power Demand Side Management and Intelligent Power Monitoring Technology in Coking Industry
I. Analysis of power consumption characteristics of industry users
The coking industry refers to the industries that produce and operate coke, as well as the associated gases such as coal gas, coal tar, and crude benzene that are produced during the production of coke, and they are formed by recycling and processing. Coking products are widely used in the chemical industry, pharmaceutical industry, and refractories. In recent years, the rapid development of the iron and steel industry has driven the rapid growth of China's coking industry.
Coking industry electricity load characteristics:
1) Most equipments need continuous operation, such as coke oven, circulating water system, gas recovery device, etc.;
2) Some can be intermittently produced, such as machining equipment and coal blending system.
The electricity used for coking production belongs to the first and second power loads, and the power supply should be a dual power supply. The two-way power supply should be powered by the master-backup mode. In order to meet the production power, the coking production and distribution system is generally set up two workshop substations - coal coke substations, recycling substations.
Coking 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 cookers, blowers, plant road lighting
general
Auxiliary production load
Refrigeration unit, air conditioner, boiler
important
The main productive load
Coking equipment: tamping coke oven, quenching coke oven, cool coke table, electric vehicle, hydraulic switch, six-hammer tamping machine, rotary crane, grab crane, electric winch, wheel loader;
Purification and recycling equipment: horizontal tube primary cooler, electric tar catcher, cyclone tar catcher, ammonia wash tower, benzene wash tower, desulfurization tower
important
Safeguarding load
Workshop lighting, accident lighting, maintenance lighting
general
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 that is not affected by time, season and climate.
2. Emergency peak load limitation can quickly disable office equipment such as office, lighting, computer fax machines, etc. During the peak hours, equipment such as factory lighting can be stopped at intervals, and some auxiliary production equipment can be disabled, for example, cooling. Units, air conditioners, boilers, but without prejudice to safety. Strong emergency peak shifting capacity, purification and recycling equipment: such as cross-tube primary cooler, electric tar catcher, cyclone tar catcher, ammonia wash tower, benzene washing tower, desulfurization tower and other important (high-risk) electricity load, not suitable for rapid Avoiding the wrong peak.
3. The phase shift of users in this industry can be carried out by arranging for centralized inspections and production cuts. For example, if centralized repairs are used, only the maintenance of workshop lighting, accident lighting, maintenance lighting, and other maintenance equipment will be reserved. Generally, about 1,000 kilowatts of maintenance will be reserved. The load can be; if the production method is adopted, the coking equipment and supporting auxiliary systems can be gradually stopped 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:
On the premise of ensuring safety, the coke oven was stopped at 8:00 to 22:00 for roiling furnace processing to reduce the output and achieve the peak load shift effect.
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) Prioritize the peaks of the air-conditioning system, office and lighting system, and then gradually release the load according to the instructions.
(II) Gap Level III Participation Plan
1. Staged peak shift:
On the premise of ensuring safety, based on the implementation of the IV-grade plan, some machining equipments will be added and stopped at 8:00 to 22:00 to participate in the peak load shift, and the coke oven will be used as a stifling furnace to further reduce the output and thus meet the peak-to-peak requirements. .
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, additional machining equipment is added to participate in the peak load shift, and part of the production load is reduced so as to meet the peak-to-peak requirements, and then gradually release the load according to the directive 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 level III program, stop and increase the total machining equipment and coal blending system equipment from 8:00 to 22:00 to further reduce the output, thus meeting the peak load shifting requirements.
2) For the purification and recovery equipment with slow response time, it is necessary to prepare for the wrong peak preparation in advance to 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 Level III program, quickly stop all machining equipment and coal blending system equipment to meet the peak-to-peak requirements, and then gradually release the load according to the instructions.
(IV) Gap Level I Participation Plan
1. Staged peak shift:
Taking into account the large power gap, companies can arrange for overhaul of the entire plant, only to maintain the power load required to repair equipment.
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) Taking into account the safety of production in this industry and the ease with which production can be resumed, on the basis of the implementation of the Level II plan, no additional production equipment is additionally restricted. Then gradually release the load according to the instruction.
Fourth, the industry users involved in the peak load shifting risk and precautions
1. Sudden power cuts in furnaces, fires, etc. in production areas of production companies in this industry may easily lead to leakage of coal gas, causing environmental pollution, severe poisoning accidents or serious economic losses. It is recommended that centralized production be adopted. The way of centralized maintenance is to complete the production tasks in advance in this month, and to avoid peaks or annual maintenance during the remaining days at the end of the month.
2. From a safety point of view, such as purifying the product recovery workshop (gas purification), if there is a sudden power outage, it will lead to major accidents. The reason is that the gas from the coke oven reaches 82°C. If there is a power outage, the fan stops, the gas overflows. Explosions and poisoning and other personal injuries occurred. For coke ovens, if there is a power outage, the coke oven will be scrapped and the same gas may explode.
Therefore, users of the industry should formulate effective emergency plans as early as possible. When participating in the peak shift, they should take the initiative to cooperate with the wrong peaks and communicate with the power supply companies in a timely manner. It is advisable to adopt inspections or rotations to avoid the use of compulsory pull-in or remote control devices to control power cuts. Violent accidents take the initiative to shoulder social responsibilities while minimizing losses.
5.1 Project Overview
Uttam Steel in India constructs 500,000 tons of pig iron mill in Wardha, Maharashtra (Wardha region is rich in coal and iron ore resources, and is easily accessible by roads and railways) The supporting project includes a sintering plant and a 500,000 tons coking plant. The entire project is expected to invest 11 billion rupees ($228 million).
The construction of 500,000 tons of coking plant includes coal preparation plant, coking plant, gas purification plant and other production facilities and supporting public auxiliary facilities; as the energy supply area of ​​other plant areas, the distribution security is particularly important and the requirements are higher. The power control must be safe, reliable, and fast, and manual operation on the spot can no longer meet the actual requirements of the project. Ankerui Electric Co., Ltd. entrusted with Shanghai Delixi Co., Ltd. to go to the on-site construction and commissioning of the intelligent power system at the India Coking Plant; mainly completed the 6.6KV power distribution system and 0.4KV power distribution system in the coking plant for centralized monitoring to ensure coking Factory power supply system is operating normally.
1 field device layer
The 6.6KV system topology is shown in Figure 1. The 6.6KV high-voltage power distribution cabinet mainly consists of two incoming cabinets (main incoming cabinet and standby incoming cabinet), two PT cabinets, four transformer outlet cabinets, and two The motor outlet cabinets and a mother unit are prepared for the investment. In this system, Ankerui Electric Co., Ltd. in order to meet the requirements of the user in the high-voltage loop circuit and in line with the principle of cost savings for the user, the field device layer configuration: choose 2 ACRM4 for my company on the 2-way line cabinet. -F comprehensive protection (LCD display, circuit protection and monitoring device, integrated monitoring and control device, fault recording, SOE event recording, remote communication, etc.); 2 ACRM4-M integrated protections are selected for use on 2 motor outlets (LCD display, motor protection, integrated monitoring and control device, fault recording, SOE event recording, remote communication, etc.); 4 ACRM4-T integrated protection (LCD display and distribution) for 4 transformer outlets Electrical protection monitoring and control device, integrated monitoring and control device, fault recording, SOE event recording, remote communication and other functions); 2 ACRM4-U (LCD display, two-section PT power supply switching, PT is selected for 2 PT cabinets) Comprehensive protection of the cabinet, integration of measurement and control devices, fault recording, SOE event recording, and remote communication functions;) 1 ACRM5-B is selected for use on a single parent unit. LCD display, prepared from the cast protection, monitoring and control system integration, fault recording, SOE event logging, remote communications and other functions).
As shown in Fig. 2, it is a 0.4KV system A topology diagram, which mainly monitors the three-phase current, voltage, and electrical parameters of the pump room. Ancorui Electric Co., Ltd. according to the needs of customers, to the power distribution station equipped with PZ42-E4 power meter, the power meter can measure three-phase current, three-phase voltage, active power, reactive power, power factor, power, etc. , Embedded installation method; fully meet customer requirements, and easy installation, cost-effective.
As shown in Figure 3, it is a 0.4KV system B topology, which mainly monitors the electrical parameters of the coal preparation plant and the coking plant. Users mainly check the motor three-phase current, voltage, electrical degree and other electrical parameters and view the motor running status and modify the fixed value.
Ancorui Electric Co., Ltd. also provides power meters equipped with PZ42-E4 to collect electrical parameters in the field according to the needs of customers (motor protection devices are equipped with other manufacturers on the motor protection circuit).
2 Communication Management
Communication management layer: Adopt Taiwan MOXA CP134U-I communication expansion card, with over 800 Kbps data throughput, the world's best performance, 4 ports with ADDCTM RS-422/485 interface speed up to 921.6 Kbps, 4-wire RS-485 transmission distance Up to 1.2 km, built-in 15 KV ESD surge protection or optional 2 KV optical isolation protection, support for 128 byte FIFO drivers and built-in hardware and software flow control, universal PCI compatible 3.5/5V PCI and PCI -X, supports Windows 2003/XP/2000/98/ME, Linux, UNIX drivers, and provides space-saving low profile communication multi-serial cards to choose from.
3 station control management
Configured as EVOC IPC-810B Core2 2.66G / 1G/160G + 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: 1G
Hard Disk: Monitoring Workstation 160G
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 floor, 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 for 30 minutes
5.3 System Functions
(a) User Rights Management
For different levels of users, set different permissions to prevent the loss caused by human misoperation to production and life, and realize the safe 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.
User rights management is particularly important in this project, because in the 6.6KV system, all integrated protections on the site must be controlled. The setting of high authority guarantees the on-site operation's normative eligibility. At the same time, it has an operation ticket setting. The order of remote control of the high voltage cabinet.
The system provides simple, easy to use, and good user interface. Adopts full English 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 Display etc.
On the 6.6KV system primary map, the on-site circuit breaker operating status, handcart position, and grounding switch status can be seen through changes in the screen colors (red indicates the closing state, green indicates the opening state, and gray indicates the separation status of the trolley). , spring energy storage status.
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, power, etc.) of the 6.6KV loops; log in to the highest authority user and you can realize the circuit breaker on the site. Realize the closing and closing control, view the comprehensive security setting, and modify the setting value online. 
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 Power Meter
ACR220EL
only
100
Ankerui
PZ Series Programmable Smart Meter
PZ42-E4
only
68
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] Coking industry shift peak power limiting technical guidance.
The function and application of intelligent power monitoringSmall Hole Driling Machine,Small Driller,Residential Water Well Drilling,Small Bore Drilling Driling Machine
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