1747-RL302羅克韋爾
1747-RL302,allen-bradley
1747-RL302美AB
每家生產工廠都很關注電力管理。
自主提供部分電能的工廠尤其關注這一點，特別是在工廠需要依靠電力實現持續運行時。位於密歇根的一家造紙廠便是如此。
斷電可能導致停機、生產損失以及設備損壞，代價高昂。為緩解此問題，電力質量的重要性日漸凸顯;由於容差範圍窄，設備和制造過程中很難利用質量差的供電。
造紙廠尤其受到此類問題的困擾。
在與羅克韋爾自動化電力及能源管理解決方案小組(PEMS) 合作之前，該造紙廠一直在承受每年四至七次斷電帶來的負面影響。
為幫助像們這樣每天依靠電力實現贏利的工廠，PEMS專門設計了一套解決方案來連續測電力，並控制負載的自動切換，以維持工廠的正常生產。除此之外，整套解決方案還能提供分析和培訓，幫助工廠員工更深入地了解電力管理挑戰，以及如何應對這些挑戰。
面臨的挑戰
面臨的挑戰是如何掌握電力使用情況，並在不中斷造紙過程的前提下切換電源。
該廠有兩臺造紙機專門生產用作包裝材料的瓦楞紙板。工廠總負載的60%由現場的15兆瓦渦輪發電機承擔，其餘部分則由當地公共電力提供。過去，在當地公共電力停止供電時，渦輪發電機就需要滿足整個工廠的負載需求，進行導致其跳閘離線，斷電屢有發生。
這些電力故障造成整個工廠長時間停機、設備受損、生產受阻。之後，還需要耗費大量精力使工廠恢復生產。
解決方案
在權衡PEMS解決方案的價值以及斷電造成的收益損失之後，該公司認為這一投資物有所值，因此決定由PEMS開發一套緊急負載卸載係統解決方案。
PEMS為該廠提供了一套負載管理及控制係統(LMCS)，其中配備的自動切換係統可以快速從正常運轉模式轉換到應急模式，以滿足工廠中關鍵的電力需求。PEMS解決方案基於成熟且極為可靠的Allen-Bradley可編程邏輯控制器和電力測器係列產品，可使渦輪發電機、鍋爐及關鍵設備持續運轉，保證工廠造紙過程不被中斷。該係統能將非關鍵負載切換為離線狀態，並能在不到266ms或12個周期的時間內將工廠從公共電網中隔離出來。
LMCS可對電壓、電流及其它電力參數進行實時視。其中包含的緊急負載卸載算法可實現對非關鍵負載控制(卸載)的快速響應。切換過程只需幾毫秒，因此，當主要的公共電力中斷時，完全可以通過輔助電源維持關鍵負載的運轉，從而維持生產。LMCS還會提示和記錄異常事件(報)，連續視公共電網提供的電力，在遇到緊急情況時幾乎可以瞬間自動將負載切換為離線狀態，從而確保13.8kV線的穩定。
在構建係統之前，PEMS先進行了現場調查和需求分析。們制定了包含I/O及電力測器詳細列表的功能規範，確定了將要採用的通信網絡，並且明確了將所有功能整合在一起所需的硬件和軟件。
此外，們還與工廠溝通確定了人機界面(HMI)站的配置，同時定義了將未來擴展考慮在內的自動化控制算法和要求規範。
PEMS提供的解決方案中還整合了其它一些服務，例如軟件和硬件工程、設計和起草、面板裝配以及PLC編程。工廠驗收試驗也順利執行。整個解決方案安裝到位後，工廠得到了一套終文檔，從而完成了所有設計及操作知識的交接。
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