1771-CFMK
1771-CFMK
1771-CFMK
每家生产工厂都很关注电力管理。
自主提供部分电能的工厂尤其关注这一点,特别是在工厂需要依靠电力实现持续运行时。位于密歇根的一家造纸厂便是如此。
断电可能导致停机、生产损失以及设备损坏,代价高昂。为缓解此问题,电力质量的重要性日渐凸显;由于容差范围窄,设备和制造过程中很难利用质量差的供电。
造纸厂尤其受到此类问题的困扰。
在与罗克韦尔自动化电力及能源管理解决方案小组(PEMS) 合作之前,该造纸厂一直在承受每年四至七次断电带来的负面影响。
为帮助像们这样每天依靠电力实现赢利的工厂,PEMS专门设计了一套解决方案来连续测电力,并控制负载的自动切换,以维持工厂的正常生产。除此之外,整套解决方案还能提供分析和培训,帮助工厂员工更深入地了解电力管理挑战,以及如何应对这些挑战。
面临的挑战
面临的挑战是如何掌握电力使用情况,并在不中断造纸过程的前提下切换电源。
该厂有两台造纸机专门生产用作包装材料的瓦楞纸板。工厂总负载的60%由现场的15兆瓦涡轮发电机承担,其余部分则由当地公共电力提供。过去,在当地公共电力停止供电时,涡轮发电机就需要满足整个工厂的负载需求,进行导致其跳闸离线,断电屡有发生。
这些电力故障造成整个工厂长时间停机、设备受损、生产受阻。之后,还需要耗费大量精力使工厂恢复生产。
解决方案
在权衡PEMS解决方案的价值以及断电造成的收益损失之后,该公司认为这一投资物有所值,因此决定由PEMS开发一套紧急负载卸载系统解决方案。
PEMS为该厂提供了一套负载管理及控制系统(LMCS),其中配备的自动切换系统可以快速从正常运转模式转换到应急模式,以满足工厂中关键的电力需求。PEMS解决方案基于成熟且极为可靠的Allen-Bradley可编程逻辑控制器和电力测器系列产品,可使涡轮发电机、锅炉及关键设备持续运转,保证工厂造纸过程不被中断。该系统能将非关键负载切换为离线状态,并能在不到266ms或12个周期的时间内将工厂从公共电网中隔离出来。
LMCS可对电压、电流及其它电力参数进行实时视。其中包含的紧急负载卸载算法可实现对非关键负载控制(卸载)的快速响应。切换过程只需几毫秒,因此,当主要的公共电力中断时,完全可以通过辅助电源维持关键负载的运转,从而维持生产。LMCS还会提示和记录异常事件(报),连续视公共电网提供的电力,在遇到紧急情况时几乎可以瞬间自动将负载切换为离线状态,从而确保13.8kV线的稳定。
在构建系统之前,PEMS先进行了现场调查和需求分析。们制定了包含I/O及电力测器详细列表的功能规范,确定了将要采用的通信网络,并且明确了将所有功能整合在一起所需的硬件和软件。
此外,们还与工厂沟通确定了人机界面(HMI)站的配置,同时定义了将未来扩展考虑在内的自动化控制算法和要求规范。
PEMS提供的解决方案中还整合了其它一些服务,例如软件和硬件工程、设计和起草、面板装配以及PLC编程。工厂验收试验也顺利执行。整个解决方案安装到位后,工厂得到了一套终文档,从而完成了所有设计及操作知识的交接。
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