1. Introduction
1.1. Overview
Industry is the largest consumer of energy in my country, accounting for approximately 70% of the country's total energy consumption. Different types of industrial enterprises have varying impacts on energy consumption due to their different processes, equipment conditions, product types, and energy management levels. Establishing a centralized and unified energy management system across the entire plant enables online collection, calculation, analysis, and processing of energy data, playing a crucial role in energy and material balance, scheduling and optimization, and the operation and management of energy equipment.
Energy Management System (EMS) is an important component of enterprise information systems. Therefore, in the architecture of enterprise information systems, energy management is regarded as a basic application component of the MES system and an important part of the automation and informatization of large enterprises.
1.2 Overall Requirements Analysis
The company aims to establish an energy management and dispatch center using advanced automation and information technologies to achieve automated, efficient, and scientific management of the entire process, from energy data acquisition and process monitoring to energy medium consumption analysis and energy management. This will organically integrate energy management, energy production, and energy use, enabling offline production analysis and management using advanced data processing and analysis technologies. This includes energy production management statistical reports, balance analysis, performance management, and predictive analysis. It will also achieve unified dispatching of the entire plant's energy system, optimize energy medium balance, maximize energy efficiency, improve environmental quality, reduce energy consumption, and ultimately achieve energy conservation, emission reduction, and improved overall energy management.
2. Design Content and Principles
2.1 Design Content
★Automation System
Energy management center network system and equipment system;
Energy management center hardware and software platform system;
Data acquisition systems at various sites within the energy system;
Human-machine interface systems required for dispatching and operation personnel;
Equipment redundancy, safety monitoring system;
Systems for storing and analyzing massive amounts of historical data, etc.
★Auxiliary System
Video security monitoring of energy systems;
Energy system equipped with alarm system;
Large-screen display systems for energy systems, etc.
2.2 Design Principles
★Improve the collection, storage, management, and utilization of energy information.
★Standardize the design of automated systems for energy systems
★ Achieve decentralized control and centralized management of the energy system
★Reduce energy management steps, optimize energy management processes, and establish an objective energy consumption evaluation system.
★Reduce energy system operating costs and increase labor productivity
★Accelerate the handling of energy system failures and anomalies, and improve the plant-wide response capability to energy accidents.
★ By optimizing energy dispatch and balancing command systems, energy can be saved and the environment improved.
★This provides conditions for further mining, analysis, processing, and handling of energy data.
3. System Architecture
A typical energy system architecture includes a three-tiered physical structure consisting of an energy dispatch and management center, a communication network, and remote data acquisition units (as shown in the diagram below).
4. ForceControl Enterprise Energy Management System Integrated Solution
ForceControl Technology provides comprehensive solutions for enterprise EMS management systems. A typical energy system architecture includes a three-tiered physical structure: an energy dispatch and management center, a communication network, and remote data acquisition units. The information acquisition and protection features are as follows:
Energy "blind spot" information collection: The ForceControl data acquisition manager can be installed on-site and follows the low power consumption design principle. It has remote management functions, making it convenient for deployment and upgrades.
Information security protection: ForceControl can fully guarantee the security of enterprise production information, not only completing the transparent transmission of industrial standard protocols, but also preventing network attacks such as illegal intrusion.
Energy Information Management: The ForceControl Energy Management System can fully and effectively manage energy information and establish reasonable energy strategies.
The Likong Energy SCADA integrated management platform software analyzes the characteristics of energy-consuming equipment and adds appropriate retrofit equipment to improve equipment performance, increase the efficiency of electrical equipment, and reduce raw material losses. It rationally schedules maintenance based on equipment operating history, effectively increasing safe operating time and reducing maintenance costs. Alarm parameters are set to promptly alert when equipment is unstable, ensuring safe operation. The platform centrally monitors, measures, controls, and manages enterprise energy, enabling real-time and historical data storage, querying, analysis, and statistics, thus automating energy management. It fully utilizes real data as the basis for energy-saving operation analysis, avoiding human error and helping enterprises strengthen energy consumption and accounting management, making enterprise management more scientific.
4.1 Energy Management and Dispatch Center
The energy management and dispatch center consists of a real-time database server, a historical database server, a web publishing server, an operator station, and a digital large-screen display system.
The design employs a real-time database to acquire and control on-site energy data and equipment, and performs calculations, analysis, and statistics on the acquired data. The system is configured with two redundant real-time data/data acquisition servers to achieve data acquisition and control of the entire energy system, and also serve as application servers.
The real-time database uses pSpace, a Linux-based real-time database developed by Beijing 3D Force Control Technology Co., Ltd. pSpace is a large-scale real-time database software with independent intellectual property rights and has been widely used in multiple large-scale energy dispatching systems. Its key technical indicators, such as reliability, stability, data compression ratio, and response speed, are the same as or close to those of internationally renowned brands.
The SCADA/HMI software uses eForceCon SD configuration software developed by Beijing 3D Force Control Technology Co., Ltd. This product has excellent compatibility with Force Control pSpace, enabling seamless integration. Its openness and stability have also been proven in long-term application.
4.2 Main Functions of the Energy Dispatch Center System
1) Data acquisition function
The ForceControl Energy SCADA integrated management platform software acquires various energy data of the enterprise and enables real-time monitoring, alarm, analysis, calculation, and statistics of enterprise operation data.
2) Monitoring function
The system monitors and adjusts each subsystem in real time. It enables energy production flow monitoring, system fault alarms and analysis, and optimized system scheduling. As a support system for the energy production scheduling and control center, it is responsible for daily energy production scheduling, ensuring normal and orderly production on the main production line, and implementing emergency energy scheduling strategies during unforeseen events to ensure a safe and stable energy supply, achieving energy conservation and efficiency.
3) Basic energy management functions
The collected data is summarized, analyzed, and organized, and combined with production plan data to carry out basic energy management work, including energy performance analysis and management, energy quality management, energy balance management, energy forecasting and analysis, and energy system operation support management (including task order management and power flow analysis).
4) Large screen monitoring function
A large screen for displaying energy system information is set up in the energy management and dispatch center to enable remote monitoring of video information on key on-site operating conditions of the energy system, and to comprehensively monitor energy management data and status information of various subsystems.
4.3 Energy Management Center Control Content
The energy management center control system is a computer system that integrates process monitoring, energy facility management, energy dispatching and balancing, and analysis and optimization.
The main control and management functions of the energy management and dispatch center are as follows:
1) Energy control
Energy data (including statistical and forecast data) is periodically centralized and reported, comparing actual energy consumption with expected energy consumption calculated based on actual production parameters. This improves the reliability of energy data measurement and calculation, providing a basis for enterprise leaders or management to plan, monitor, and control, and to plan energy-saving projects.
2) Energy Coordination
For continuous production systems, a powerful energy management and dispatch center is essential to coordinate the dynamic balance of individual energy medium systems and to achieve comprehensive dynamic balance among all media. Simultaneously, supporting normal system operation requires diverse and flexible adjustment techniques to coordinate energy supply and control based on production plans and energy forecasts, thus meeting the energy demands of the production process while reasonably avoiding peak loads.
3) Energy quality
By employing certain testing and analysis methods, such as quality analysis, quality tracking, trend assessment, and warnings of exceeding limits, we can conduct quality control on various energy media supplied to external parties, thereby balancing the conflict between energy media quality and product cost.
4) Energy Performance
After being processed by the server, the energy consumption data is displayed in an intuitive form as an energy network diagram, showing the distribution of energy at each workstation and providing statistical results of various energy consumption.
5) Energy Indicators
Based on the energy metering data collected by the system and combined with the product production data, the energy consumption of each production process is calculated, and energy control indicators are given to enable the assessment and management of energy performance.
6) Energy Forecasting
The energy management and dispatch center receives energy flow and characteristic production data in real time, processes the data, compares it with the data from the previous moment, and queries the existing historical data in the database. For energy users in each process, based on different production and operation states, it uses energy information flow models or statistical methods to calculate energy forecast results and provide the development trend of energy consumption.
7) Production Management and Equipment Analysis
The system model is used to adjust the operation of energy equipment in a timely manner, and the operation pattern curve of equipment is accumulated based on the operation data of individual equipment. Once abnormal operation of equipment is detected, alarm information is issued in a timely manner. With the accumulation of a large amount of equipment operation data, the operating status and service life of the equipment are analyzed to provide a basis for planned maintenance of the equipment.
5 Conclusion
The PowerControl Energy Management System platform, through reasonable energy-saving strategies and an energy consumption monitoring system, can effectively reduce the energy consumption of enterprise utilities. By analyzing utility data and establishing energy consumption models, it identifies areas for energy improvement within the enterprise. Comprehensive monitoring of various data eliminates information silos and energy-saving blind spots, thereby helping enterprises achieve sustainable development.
