I. Analysis of power consumption characteristics of users in the industry
The “photovoltaic industry†is based on the application and development of silicon materials for the industrial chain, including the production of high-purity polysilicon raw materials, production of solar cells, production of solar cell modules, and manufacturing of related production equipment. Photovoltaic power generation is considered to be the most promising renewable energy source in the future. At present, China's photovoltaic industry cluster has taken shape, and a nationwide and even global photovoltaic production base has been established in Jiangsu and other provinces.
The industry generally adopts 110kV or 220kV power supply for large-scale production (and is operated in the same way with two channels). The power load is large, and the production nature is three-shift continuous operation, and is not affected by time, season and climate.
Photovoltaic 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
Thermal energy conversion station, compressed air station, circulating water station, purification plant and so on.
important
The main productive load
1. Silicon rod silicon ingot silicon block production line: complete production line, ingot furnace, crucible, growth furnace, other related equipment
2. Silicon wafer production facilities: complete production line, cutting equipment, cleaning equipment, testing equipment, other related equipment
important
Safeguarding load
Hydrogen Chloride Synthesis Furnace, Trichlorosilane Boiling Bed Pressurized Synthesis Furnace, Trichlorosilane Hydrolysis Gel Treatment System, Trichlorosilane Crude Distillation, Distillation Column Purification System, Silicon Core Furnace, Energy Saving Reduction Furnace, Phosphorus Detection Furnace , Silicon rod cutting machine, corrosion, cleaning, drying equipment, reducing exhaust gas dry recovery device; other, including thermal energy conversion station, compressed air station, circulating water station, purification plant and so on.
important
II. Analysis of major users of electricity in the industry
1. The main electrical equipment in the photovoltaic industry includes ingot furnaces, crucibles, growth furnaces, and cutting equipment. Among them, the single crystal furnace avoids peak response time of 72 hours, and slicers and splitters avoid peak response times of 5 to 6 hours. The industry has a large load of electricity and continuity and important (high-risk) nature. It is not suitable to participate in emergency peak shifting. It can be arranged to participate in phase-shifting peaks.
2. In the case of emergency peak load limitation and power limitation, only the auxiliary production equipment such as office lighting, computer facsimile machines, plant lighting and other non-productive electrical equipment and certain purification plant can be quickly deactivated without endangering the safety production. The ability to trip peaks is weak.
3. The phase-shifting of users in this industry can be carried out by arranging centralized inspections, rotations, and stopping production lines.
Third, the industry users involved in the peak load limitation technology program
(I) Gap Level IV Participation Plan
1. Staged peak shift:
Non-productive load saving management, such as: office lighting, computer fax printing and other office electrical appliances, split and central air conditioning, cafeteria rice cooker, blower, plant road lighting, etc., reduce or disable during each period .
2. Emergency peak shift:
Immediately disable intermittent non-productive loads such as central air conditioning.
(II) Gap Level III Participation Plan
1. Staged peak shift:
Non-productive load saving management, such as: office lighting, computer fax printing and other office electrical appliances, split and central air conditioning, cafeteria rice cooker, blower, plant road lighting, etc., reduce or disable during each period . In the early morning peak, waist peak and late peak period, the non-continuous production load such as pump stoppage, slicer, and cross-section machine was about 40% of the total load.
2. Emergency peak shift:
Immediately disable intermittent non-productive loads such as air-conditioning systems, office and lighting systems.
(III) Level II Participation Scheme for Gap
1. Staged peak shift:
The use of centralized production and centralized overhaul means that the planned production tasks are completed in advance or over-fulfilled, and the rest of the working days are arranged for workers to take turns or equipment maintenance to meet the requirements of avoiding peaks.
2. Emergency peak shift:
Immediately disable non-productive loads such as air conditioning systems, office and lighting systems, electric cookers, and plant lighting.
(IV) Gap Level I Participation Plan
1. Staged peak shift:
The centralized production and centralized overhaul methods are used to complete the scheduled production tasks in advance or over-subscription. The rest of the working days are arranged for workers to take turns, equipments are overhauled or part of the production lines are deactivated to meet the requirements of avoiding peaks.
2. Emergency peak shift:
Immediately disable non-productive loads such as air conditioning systems, office and lighting systems, electric cookers, and plant lighting.
Fourth, the industry users involved in the peak load shifting risk and precautions
The industry is a continuous production industry and is a high-risk industry. Sudden power outages can cause equipment damage and casualties. For peak-to-peak power cuts, the industry must be notified 72 hours in advance to stop the production line from cutting production or to arrange centralized inspections and to prevent the following accidents from occurring:
1. Sudden loss of power in the polysilicon production process, especially the transportation of toxic and harmful gases and combustible gas equipment to stop working, resulting in positive pressure in the system, resulting in external emissions, causing great pollution to the environment, and even explosion, in a larger range Inflicts harm or fatality on the inside, resulting in serious consequences.
2. The circulating cooling water pump is a cooling device used to protect the equipment in the chemical production process. Stopping work after the auxiliary cooling system loses power will also cause damage to the furnace body, resulting in equipment accidents, which will directly affect the recovery cycle and cause major losses. Severe fire and personal injury may result.
3. The main function of the process fan is to transport the materials, air and cooling required for the chemical reaction on the production line. Once the power is lost, the proportion of other materials in the reaction equipment will be too high to cause the batch product to be scrapped or cause damage to the equipment or even cause personal injury.
4. Fire-fighting pumps are security facilities that flammable and explosive chemical companies maintain their pressures during normal production and operate normally. If a power failure occurs, the fire-fighting pump cannot be rescued in time due to a fire accident, resulting in casualties.
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. It is necessary to guide enterprises to formulate effective emergency plans as early as possible, take the initiative to cooperate with the wrong peaks, eliminate the occurrence of malignant accidents, and minimize the losses.
V. Functions and Applications of Intelligent Power Monitoring
Hairun Photovoltaic Technology Co., Ltd. is one of the largest crystalline silicon solar cell manufacturers in China. Since its establishment in 2004, Hairun Solar has developed rapidly in the industry and is specialized in upstream monocrystalline rod/polycrystalline casting in the photovoltaic field. Ingot, cutting, wafer cutting and other aspects of production. Hairun Solar owns four wholly-owned subsidiaries, Jiangyin Hairun Solar Power Co., Ltd., Otsive Energy (Taicang) Co., Ltd., Hefei Hairun Photovoltaic Technology Co., Ltd. and Qiyang Ruitai Photovoltaic Materials Co., Ltd., and a holding company. The company Jiangyin Xinhui Solar Energy Co., Ltd. specializes in the production of solar cells and solar modules. At this point, the company has a complete photovoltaic industry chain from silicon rods (silicon ingots) → silicon wafers → solar cells → solar modules. . Hairun PV adopts a vertically integrated production and service model. Hareon Solar has customers and suppliers all over the world and has established good business relationships with customers. This stable and continuous supply relationship has made Hairun Solar's products make a great contribution to the world's clean energy business.
This project is the power monitoring of the polycrystalline ingot substation of Xiangyang Ruitai Photovoltaic Materials Co., Ltd. According to the requirements of power distribution system management, high-voltage cabinets and low-voltage distribution lines in polycrystalline ingot substations need to be monitored for power to ensure the safety, reliability, and efficiency of electricity usage.
Acrel-3000 power management system takes full advantage of the latest developments in modern electronic technology, computer technology, network technology and fieldbus 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 and centralized management of the power grid operation is realized.
5.1 System Structure Description
The monitoring system mainly realizes the power monitoring and power management of the 20/0.4kV distribution system of the polycrystalline ingot substation; the monitoring range is the low voltage input of 1A, 1C, 1E, 1F, 1M and 1N transformers in substations. Line cabinets, communication cabinets, feeder cabinets and high-voltage side meters, integrated protection devices for remote real-time monitoring and power management. The system has a total of 141 Ancorui smart meters, 6 temperature controllers, 12 comprehensive protections, and 10 bus lines. The low-voltage substation and the high-voltage room are not far from the duty room and are directly connected to the shielded twisted pair cable. The serial port server is finally connected to the network switch through a network cable. The monitoring host realizes the data communication between the meter on the bus and the monitoring host through the network switch.
5.2 Network Structure Topology
The monitoring system adopts a hierarchical distributed structure, namely station control layer, communication layer and bay layer;
Interval equipment layer mainly includes: multi-function network power meter, switch quantity, analog acquisition module and intelligent 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 supplies, printers, alarm buzzer and other equipment. 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.
The above network instruments all adopt 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, that is, both parties can receive and send data. Only data can be sent or received at the same time. The maximum data transmission rate is 10Mbps.
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.
5.3 System Functions
According to the site's requirements for the system, Ankerui Electric Co., Ltd. designed the project system interface and functions, the specific display interface is as follows:
1 system main interface
The main monitoring screen of the system is the high-pressure side real-time screen, which mainly monitors the running status of the high-pressure loop in real time. The red represents the closing and the green represents the opening. In the high-voltage system diagram, you can intuitively see the operating parameters and status of each high-voltage incoming and outgoing line, you can see all the conventional power parameters of the transformer outlet side, such as: three-phase voltage, current, active power, reactive power, Power factor, frequency, active power and transformer temperature.
5.4 Operational Effects
1, practicality
The system's front-end products and system software all have good learnability and operability. The management personnel with the primary operating level of the computer can master the operation essentials of the system through simple training and achieve the operation level of completing the duty task.
2, security
The system configuration of the distribution network is different from other industries. Any neglect of the system is a huge potential safety hazard. This requires that all equipment and accessories in the system should meet the relevant Chinese or international safety standards while maintaining safe and reliable performance. Can work effectively in non-ideal environments. Powerful real-time monitoring and linkage features fully guarantee the security of the user's environment.
3, real-time
Before the implementation of the project, the on-site data was mainly reproduced manually, and it was conducted twice a day. The time of each loop was not uniform, and the difference was poor. After the project was implemented, it was collected in real time in the background. The time was 50mS and the comparability was strong.
4, stability
The integrated intelligent power distribution system is a long-term uninterrupted system that monitors the operation of the distribution network and has certain functions to handle events. It requires the system to have years of successful application experience in the market, and has corresponding customers. Group and customer service system.
5, the overall analysis
Before the implementation of the project, the electricity consumption in each period and the power consumption of each loop cannot be compared horizontally and vertically. After the project is implemented, it is analyzed through the curve, and the peak-to-valley period is obviously contrasted, which facilitates peak-to-peak valley filling, and the deployment of three-phase electricity is relatively balanced.
6, scalability
The design of the system is not a layer of change. Now, after the project is expanded, modified, or compatible with other systems, etc., the system design should reserve multiple communication interfaces with other systems. The additional distribution electronic station system and the superior dispatching system can realize system expansion.
7, easy maintenance
The maintenance of integrated intelligent power distribution system during operation should be as simple as possible. From the configuration of the computer to the configuration of the system, the configuration of the front-end equipment fully considers the system reliability and implements corresponding authentication. The hierarchical management of the entire system ensures that once a failure occurs in the network, the normal operation of all devices will not be stopped due to the maintenance of a certain part of the equipment.
Sixth, the main monitoring products
(1) AC side meter selection ACR330ELH meter
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) AC side meter selection ACR220EL power meter
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) Comprehensive protection device AM5 series
AM series protection and monitoring equipment integrates protection, measurement and control. It is applicable to user terminal substations with a voltage level of 35kV and below, and can achieve comprehensive protection and monitoring of user substations. Applications cover electric power, water conservancy, transportation, petroleum, chemical industry, coal, metallurgy and other industries.
The protection device adopts advanced mature and reliable protection principles and algorithms, strong anti-interference performance, high reliability, flexible implementation of protection, and redundant design of communication. The device is equipped with an independent high-precision current measurement circuit, 16-channel switch acquisition and 10 relay output, which can be combined with Acrel-3000 power management software to enable an unattended end-user substation distribution automation system.
It is applicable to the protection and automatic control functions of equipments such as line, bus coupler, 10kV transformer, high voltage motor, high voltage capacitor and so on.
(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
name
Model, specification
unit
Quantity
Note
Field device layer
Power Meter
ACR220EL
only
134
Power Meter
ACR330ELH
only
7
Comprehensive protection device
AM5
only
12
Station control management
Workstation host
IPC610H (3.0GHz/1GB/500GB/6007LV) + Keyboard
station
1
Advantech
Workstation host
Lenovo ThinkCentre
station
1
Lenovo
monitor
L1950WD
station
1
Lenovo
monitor
19W "LCD Monitor
station
1
Samsung
UPS power supply
C1K/1KVA
station
1
SANTAK
printer
HP 1007 A4 format
station
1
HP
Console
Steel wood structure with a chair
set
1
Local procurement
Communication cabinet
K2200 (2200*600*600)
set
1
2060*800*600
Photovoltaic power monitoring software
System configuration software Acrel-3000
set
1
Ankerui
Network communication layer
Wireless data acquisition module
CM310 GSM Modem
set
1
Mao Mao
Industrial Serial Server
NPORT5630-8 RS485 interface × 8
set
11
MOXA
Ring network switch
EDS405A
station
11
MOXA
Industrial switching power supply
KDYA-DG75-24
set
11
Huali
Photovoltaic Communication Collection Box
set
10
Optical box with accessories
Optical box, pigtail, jumper, flange
set
11
DI/DO/analog
ARTU-Z
set
10
Ankerui
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
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] Photovoltaic industry peak power limit technical guidance.
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