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Application of electric energy management system in bio-pharmaceutical industry

Views:3     Author:Site Editor     Publish Time: 2021-07-09      Origin:Site

Abstract: according to the electric energy use characteristics of biological products companies, has established accord with the actual situation of the company energy management system, this paper introduces the architecture of the system and its application in enterprises, improve the company's energy data real-time monitoring ability, optimizing the allocation of the company's energy, electric energy consumption, reduce the company targeted to solve the problem of the energy loss in the company's production activities.

 

Key words: Energy management; Data analysis; Electric energy metering; Energy conservation and emissions reduction

 

0 Introduction

Energy is an important material material to promote the development of human economy. Scientific and effective measurement and monitoring of energy resources plays a key role in the quality of products produced by biological enterprises. Biopharmaceutical companies require equipment to work continuously when producing products, and continuous energy supply is the basic requirement to achieve this condition.According to the characteristics of production and operation, enterprises should strengthen energy supervision and formulate a reasonable energy management system, which can not only improve production efficiency, but also reduce production costs, so that enterprises can have stronger competitiveness in the market.

 

1 Brief introduction of enterprise electric energy consumption

 Biomedicine industry is a high-tech industry with high technology content, high investment, high income and high risk. Its high technology is not only reflected in the high standards and strict requirements of product quality, but also reflected in the high requirements of production equipment and production environment. Long r&d cycles and high upfront costs have led to large investments in clean plants and other public energy system facilities that meet GMP requirements and biological product standards.

According to our company's annual main energy consumption statistics, the total energy consumption is about 20,000 tons of standard coal. According to the investigation and analysis, the energy system operates with load all year round, and the energy consumption changes periodically with season and time. In summer and winter, the energy consumption is large, while in spring and autumn, the energy consumption is small. The energy consumption is large in the day and small at night, and the energy operation is unbalanced.

 

2 Architecture of the Electric Energy Management System

Energy management system is a real-time management system integrating energy measurement, data transmission and analysis.Relying on wired network communication, it can realize real-time monitoring of enterprise power system, comprehensive statistical analysis of energy consumption, cost allocation, and analysis of advanced characteristics of energy-consuming load equipment, so as to realize optimal allocation of energy and achieve better energy conservation and emission reduction. 

The enterprise energy management system consists of online monitoring data acquisition system, energy data transmission system, energy operation supervision system, energy efficiency analysis and management system, etc.

 

2.1 Power energy management system functions

The energy management system is mainly composed of energy supervision, monitoring and energy information platform. The energy management platform consists of server, database, intelligent data collector and front-end machine. Energy monitoring system is a processing platform for collecting, counting and analyzing energy consumption data. Energy information platform is a collection layer network platform composed of terminal energy consumption meters.

 

2.2 Electric energy collection method

With the gradual improvement of the first, second and third level energy metering equipment of our company, there are higher requirements on the effectiveness and accuracy of energy source data, and the manual meter reading method can no longer meet the above requirements.In order to realize real-time and accurate data management, it is necessary to replace traditional manual operation with intelligent acquisition equipment with advanced technology, high precision and good reliability.

The power supply nature of our company is the load enterprise, the central distribution room is the double circuit power supply. The workshop adopts electronic power meter to measure the electric energy, which can provide the basic measurement data of three-phase voltage, current and power with high precision, and has multiple functions such as compound rate calculation, demand calculation, harmonic calculation and so on. Modular design for easy function expansion and large screen display for easy data reading. According to the number of electricity meters assembled, the workshop chooses intelligent data collector with port 16, port 8 and port 4 to meet the requirements. As a bridge between metering equipment and control host, the collector's protocol conversion function can replace the preprocessor to select different acquisition protocols, collect real-time data of various intelligent equipment, and realize information summary and processing.

 

2.3 Network communication function

    The energy monitoring system adopts bus, RS485 communication line, ethernet line, optical fiber and other communication modes. The system is compatible with other communication devices, and displays the running status and online running parameters of the energy system by monitoring the large screen. According to the energy monitoring requirements related to the project, each energy subsystem diagram can be modified and configured according to the requirements or actual operating conditions, and the system will reflect the operation parameters in real time according to the modified conditions.

 

3 Application of electric energy management system

The power energy management system releases energy data to the company's LOCAL area network. Specific indicators include real-time monitoring, statistical reporting, analysis and comparison, accident alarm, target management, energy conservation assessment, etc. Managers and technicians can read the relevant data under the appropriate authority. The platform can fully reflect a variety of functions, interface clear, easy to understand, easy to understand.

 

3.1 Energy management system functional composition structure

The functional structure of the energy management system is shown in Figure 1, Figure 2 and Figure 3.

 图片1

Figure 1 Structure diagram of energy efficiency analysis and management subsystem

 图片2

Fig.2 Structure diagram of energy operation supervision subsystem

 图片3

Fig.3 Structure diagram of energy data acquisition and transmission subsystem

 

3.2 Energy management system functions

3.2.1  Power data acquisition

(1) There are two ways of energy consumption data collection: intelligent equipment collection and manual meter reading. The collector can save the historical data of 15 ~ 30 days independently to prevent the replacement of data after network interruption and recovery.

(2) Automatic collection of intelligent instrument data support RS485, M-BUS or Ethernet standard interface and standard MODBUS, DLT-645, CJT-188 and other communication protocols, for the use of non-standard protocol instrument support communication interface program development, to ensure the normal data collection.

(3) The interval of automatic data collection is no more than 1 min. The data storage interval can be flexibly set according to actual requirements. The storage interval supports 5 min. 

(4) Main acquisition parameters include three-phase voltage, three-phase current, active power, reactive power, power factor, electric degree, etc.

 

3.2.2 Power data report

(1) The system provides daily, weekly, monthly, quarterly and annual reports of energy consumption statistics in fixed formats such as classification, itemization and subdivision. 

(2) The system supports the creation of new energy consumption statistics that meet the actual management needs of managers. 

(3) All reports support manual generation and regular automatic generation and mail distribution. 

(4) All system reports can support office automation software(Excel).

 

3.2.3 Equipment information management

(1) Metering instrument information management. It can flexibly define the energy use attribute and ownership relationship of measuring instruments at each collection point, and the system can automatically complete the corresponding energy consumption data statistics according to the instrument attributes. Visual monitoring of on-line status of metering instruments, and the realization of instrument fault alarm; Conduct integrity statistics of instrument data, evaluate the validity of data in case of missing data, and remind operators to check and maintain; Supports remote query and setting of internal parameters of the instrument, including instrument address, communication rate, wiring mode, CT variable ratio, PT variable ratio, etc. 

(2) Energy equipment information management. The system can realize the classified management of equipment according to the attribute of equipment energy use. Can monitor the running state and key parameters of energy-using equipment, establish equipment asset management and maintenance management files; Manage the historical maintenance record and maintenance plan of the equipment online to make the production process safe and stable.

 

3.2.4 System safety management

(1) User management. The system can create and delete users as needed, allowing administrators to be responsible for managing users within a group. 

(2) Authority management. The system login needs to be verified by user password and permission, and all operational events are recorded. It supports hierarchical authorization mechanism, and personnel with different administrative authority can access hierarchically according to system Settings.

(3) Log management. The system records/queries the user's various operations, alarm information, etc., and records/queries the error and diagnostic log information in its own operation process.

 

3.3 Energy consumption analysis and management

According to the drug production quality management standard of bio-pharmaceutical enterprises, the energy needed for production shall be managed.Energy platform based on analysis of the data of the energy in the process of enterprise production cost allocation, promotes each production workshop to improve production technology and promote the upgrading of energy-consuming equipment, realize the departments of energy consumption and production workshop benchmarking, scientific and accurate definition and analysis of the energy consumption cost of each department team, convenient financial data calculation, the energy cost allocation to each department, analysis of energy consumption departments, analyze the effect of energy consumption cost based data maintenance, etc.

 

4 Introduction of Acrel industrial energy consumption management platform

4.1 Platform Architecture Introduction

Acrel energy management and control system adopts the layered and distributed network structure, which has good reliability and real-time performance. It is mainly composed of three parts: the field equipment layer (energy metering terminal), the communication management layer (communication management terminal) and the main station layer (energy monitoring platform).

The above three parts run through the whole structure of the system respectively. The overall design structure of the energy management system is designed according to the basic structure of energy management. While meeting the above three parts, part of the analysis, monitoring, decision-making and release platform is added.

 

 图片4

FIG. 4 Architecture composition of industrial energy consumption management platform

 

 图片5

FIG. 5 Function diagram of industrial energy consumption management

 

4.2.1 Visual presentation

Display the total amount of energy consumption, discount value, energy cost, energy consumption trend, proportion of energy consumption by item, regional energy consumption comparison, as well as current weather conditions and pollution situation, and display the energy consumption dynamics of important processes or sections of the enterprise in three dimensions.

 

4.2.2 Real-time monitoring

Real-time monitoring of energy use and alarm at each point of the enterprise. In this way, enterprise users can monitor the operation of each point in real time and grasp the alarm of the point more quickly.

4.2.3 Energy consumption statistical

From the types of energy use, monitoring area, production process/section time, disciplines such as dimension, use curve, pie charts, histograms, cumulative figure, digital table can use statistics, year-on-year, from analysis of the enterprise, the contrast, find out loopholes in the process of using energy and unreasonable place, so as to adjust the energy allocation strategy, reduce energy waste in the process of use.

 

4.2.4 Single consumption statistics

Docking with enterprise MES system, through product output and energy consumption data collected by the system, the trend chart of product consumption per unit was generated in the product consumption, and the year-on-year and sequential analysis was carried out. So that the enterprise can adjust the production process according to the product consumption, thus reducing energy consumption.

 

4.2.5Performance Analysis

The use, consumption and conversion of various types of energy are compared and assessed by KPI according to the performance indicators formulated by energy plan or quota, including day, week, month, year and designated period according to shift group, region, production line and section, so as to help enterprises understand the internal energy efficiency level and energy saving potential.

 

4.2.6Energy consumption prediction

 

By analyzing the energy consumption of the production process and production equipment of the enterprise, the calculation model of energy consumption is established, the data and model are modified according to the artificial intelligence algorithm, and the future trend of energy consumption of the enterprise is predicted and analyzed, so as to provide an effective decision basis for energy conservation.

 

4.2.7Operation monitoring

The system collects data on the energy consumption of the region, section and equipment, monitors the operation status of the equipment and process, such as temperature, humidity, flow, pressure, speed, etc., and supports the one-time operation monitoring of the transformer and distribution system.It can browse the managed energy consumption data directly from the dynamic monitoring plan, and can query the relevant energy consumption by energy type, workshop, section, time and other dimensions.

 

4.2.8Analysis report

Year, month, day of enterprise energy utilization, line loss situation, the equipment running status, operational conditions, such as statistical analysis, let users understand the operation of system, and provide data for the user base, and easy to find equipment is unusual, to find out the improvement points, and can use of mining and energy saving potential.

 

4.2.9Mobile terminal support

The APP supports Android and IOS operating systems, making it easy for users to grasp the enterprise's energy consumption, efficiency analysis, quarter-on-quarter analysis, energy consumption folding, energy use prediction, operation monitoring, abnormal alarm, etc. according to different dimensions such as energy classification, region, workshop, process, team, equipment, etc.

 

4.3Equipment selection for industrial energy consumption platform

Application 应用场合

Model 型号

Function 功能

 

 

 

 

 

 

 

 

Lighting box

 

 

 

 

 

 

 

ADL3000-E

Measurement of three-phase electrical parameters U, I, P, Q, S, PF, F, sub-item positive and reactive power statistics, total positive and negative active and reactive power statistics, infrared communication, current specifications, access through the transformer 3*1 (6) A, direct access to 3*10 (80) A, active power accuracy class 0.5s, reactive power accuracy class 2

 

 

 

 

 

 

 

 

 

 

 

AEW100

Three-phase electrical parameters U, I, P, Q, S, PF, F measurement, total positive and negative active power, reactive power measurement, 2-31 total harmonic content analysis, sub-harmonic and fundamental wave electrical parameters(voltage, current, power) measurement, support payment rate, historical power records, support RS485 communication, 470MHz wireless communication, infrared communication, active power accuracy  class 0.5S, reactive powera ccuracy  class 2. 

 

 

 

 

 

 

 

Power cabinet

 

 

 

 

APM800

Three phase (I, U, kw, kvar, kwh, kvarh, Hz, cosφ) zero sequence current In; four-quadrant energy; real-time and max requirements; this and last months' extremum; current and voltage unbalcancedness; load current bar chart display; 66 alarm types and external event record(SOE), support micro SD card record; 2DI+2DO; RS485/Modbus; LED display          

 

 

 

 

 

 

Distribution box

 

 

 

 

 

 

ARCM300T-Z

Three-phase (I,U, KW, KVAR, KWH, KVARH, HZ) single-loop residual current monitoring, 4-channel temperature monitoring, 1-channel relay output, 4-channel switch input, event recording, built-in clock, dot-matrix LCD display, 1-channel RS485/Modbus communication, optional 2G/4G/NB communication

Table 1 Industrial energy consumption management equipment selection table

 

5 Conclusion

The use and development of the company's energy management system can make up for the shortcomings of bio-pharmaceutical enterprises in energy management, and the application of digital energy information can facilitate managers to read the enterprise's energy consumption directly.Compared with the previous manual meter reading method, the automatic, real-time and intelligent energy management system greatly improves the work efficiency, and also provides conditions for accurate energy data statistics, analysis and recording in the later stage.

 

5.1  The system runs continuously, reliably and safely

The energy management system improves the function of the system according to the energy use characteristics of bio-pharmaceutical enterprises.The system can continuously and reliably evaluate and match the company's energy consumption indicators, and strengthen the monitoring of key energy consumption data and energy consumption equipment. 

 

5.2  The system is easy to operate and use

From the analysis and summary of energy management personnel to the review and approval of relevant leaders, from departmental energy management to enterprise energy summary and report, the whole work process is clear and easy to understand, in line with the overall energy management requirements and enterprise energy management standards.

 

5.3  System supervision is simple and effective

This system carries on the energy data management according to the EMS mode, causes the system operation to be concise, carries on the centralized management control to the decentralized energy data.According to the data analysis results, the corresponding solutions are proposed to achieve the energy conservation targets set by the enterprise. 

 

5.4  Implementation of fine management

Through the automatic data collection of the energy management system, the real-time and accuracy of the data are greatly improved, and the refined energy management is realized.

 

Bibliography 

[1] Shi Wei. Application of energy Management System in bio-pharmaceutical enterprises [D]. Shanghai: Fudan University, 2011.

[2] Hu Depeng, Qi Junfei, Meng Ren, JIANG Jingming, Liu Daming.Application of power Energy Management System in bio-pharmaceutical enterprises [J]. Electrical Engineering and Automation.2019.08.

[3] Design and Application Manual of Acrel Enterprise Microgrid.2020.06 edition.


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