Power Solution for Industrial Manufacturing-NET POWER

Power Solution for Industrial Manufacturing

2016/4/14 11:02:56

Power Solution for Indu

Introduction

Load analysis of Industrial Manufacturing

1. Communication Control Equipments

Communication control equipments are applied to every part of automated production chain, including process control and monitoring, automation equipment, measuring instruments, sensors, actuators, as well as other computer-aided equipments and systems, such as PLC (Programmable Logic Controller), DCS (Distributed Control System), and industrial control computers and etc. Since communication control equipments are of large quantity, wide distribution and complex application environment, whether they can work mainly depends on the quality of power supply. The higher the degree of automation, the more high-quality power is needed. For example, usually, PLC requires power supply of 50Hz, 220V ± 10% and allowed interruption time is less than 10ms. Since the data needs to be initialized if PLC is restarted, no stop should appear during working. In practical application, PLC is very susceptible to power quality, problems such as electromagnetic interference, too high or too low voltage, power outages and etc. all will cause abnormal working condition of PLC, and eventually PLC-controlled equipments even do not work, affecting the production process. But in industrial applications, above-mentioned problems frequently happen. Therefore, control communications equipments in automatic production should be supported by on-line UPS with functions of stabilizing frequency and voltage. Computers, servers and network equipments used in facility house also face various kinds of power quality issues—data loss, error code, hardware damage, etc., thus as well require the protection of on-line UPS.

2. Power Equipments

Power plants in iron and steel production are mainly motors which can be divided into two categories:

①Power drive for machinery in production, such as mill drive, constant torque load and etc. Of which, ones required technically speed regulation adopt mainly DC drive technology or AC speed regulator drive technology. For DC drive tech, DC drivers should be configured; for AC speed regulator drive tech, frequency converter should be configured. Whether DC or AC drive tech, devices related all face problems of power failure (power outages, voltage fluctuations), and then product defects and damage to production equipment occur. Thus UPS is definitely needed.

②Many supply / drainage pumps, blowers and dust-removing fans are used in steel production process. The number of fans is big and capacities of some fans are relatively large. Generally they are medium voltage motors (3-10KVac). Non-stop operation is conventional design that should be supported by MW power supply. Excitation systems of fans require separate power supply provided by UPS.

3. Information Center
With the development of steel industry, information technology, network, e-commerce mode are applied to every field including innovation, technical transformation, quality control, supply chain and etc. in this industry, realizing informatization to enhance the competitiveness. There are three levels of infomatization: network platform, business platform and enterprise applications, and the later two are both based on the first one, thus the network construction is a top priority. And safe and reliable power support facility is the foundation of network construction. So the importance of UPS is increasingly prominent.

Solutions of power supply in industrial manufacturing:

Communication Control Equipments

Since all aspects including molten iron desulphurization, continuous casting, RH turbid circulating water, refill container, blowing oxygen, muck removal, dust extraction and water cycle all adopt PLC control systems to achieve auto control, and fluctuations and interruptions in power grid will affect quality of steelmaking, in order to ensure reliable operation of the system, UPS is a must to provide clean, continuous power. Recommended capacity is 3 ~ 100KVA.

Power Equipments

Since the starting current of motors is usually 7 to 11 times than rated current, and maintain hundreds of cycles (each cycle 20ms), sharp impact caused on the UPS easily result in over current protection. Therefore UPS should be connected with motors directly and rated power of UPS should be more than five times that of the motor. For 70KW motor, 70KW × 5 = 350KW UPS is proper, considering that UPS output power factor is 0.8, thus 350KW ÷ 0.8≈440KVA is exactly what needed.

If frequency converter is equipped before motor to limit the starting current of it to a lesser extent (1 to 1.25 times the rated current), then capacity of UPS/capacity of motor can be smaller. As for this type, recommended proportion is: UPS/Frequency converter/Motor = 1.5/1.25/1. For 70KW motor, 70 × 1.25 = 87.5KW frequency converter, 70 × 1.5 ÷ 08 = 131KVA UPS can be configured.

（Combined application of UPS and frequency changer）

Information Center

As for information center in iron and steel enterprise, UPS with double-loop redundant power supply system is recommended for its highly fault-tolerant ability. NET UPS with double-loop redundant power supply system adopts two sets of three-phase high-power UPS composing into 1 + 1 parallel redundant system output as the main power supply for load equipment, 1 channel of utility (can also be another UPS ) as backup power input. For loads that need two ways of power supply, two ways respectively from the UPS parallel system and utility can directly access to the load for security; for loads that need single way power supply, redundant switches can be equipped—on which there are two input terminals and one output terminal, as long as there is one input, the output will not be interrupted. When the main circuit power supply system stop supplying power, the standby power supply works; thus greatly improves the reliability of power supply, comprehensively protect a variety of hardware devices, the program and data transmission in the iron and steel enterprise information center.

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