SBC-570

SBC-570
SBC-570
SBC-570

　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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