Power Management in a Green Factory. March 20, 2013 Mike Lin Delta Products Corp.

Transcription

1 Power Management in a Green Factory March 20, 2013 Mike Lin Delta Products Corp.

2 Power Management Challenges in a Green Factory Electricity price and consumption increase result in production cost increase Power Quality Management Presents Challenges to Factory Owners Governments set up energy saving policy and environmental requirements for industrial factories and equipment Factory Automation helps tackle increasing labor costs and production efficiency

3 Green Factory Automation Factory Energy Saving Solutions Unmanageable Industrial Ethernet Switch Renewable Energy Micro-grid Renewable Energy Micro-grid Energy Management System Unmanageable Industrial Ethernet Switch Industrial Ethernet Switch Human Machine Interface Programmabl e Logic Controller Chiller Programmable Logic Controller AC Motor Drive Cooling Tower Power Quality Management AC Motor Drive Lighting System Web IP Camera Elevator Energy Saving System Pump HVAC System Air Handling Unit Automation System for Factory Production Lines AC Motor and Drive (Applications on Injection Molding Machine, Air Compressor, Pump, Conveyor and Blower)

4 Central Control Room PC Green Factory Automation Real-Time Factory Production Line Database Assembly Line Structure Ethernet Control Panel MODBUS Control Panel MODBUS Control Panel Control Panel MODBUS Conveyer Speed Fluxing Width Conveyer Speed Conveyer Speed Hardware Controller Coating Position Control Conveyer Speed Pressure Speed Temperature Temperature Hand Insertion Fluxing Wave Soldering Semi-finished Product Testing Conformal Coating Drying

5 Power Quality Management in a Green Factory

6 Power Quality Issues at a Green Factory Grid / Transformer VFD UPS Motor Thyristor Rectifier Renewable Energy Switching Power Supply No-Linear Load Oil & Gas Industry Electronics Industry Steel Industry Process Plants Automotive Industry 6

7 What Is Reactive Power Capacitive, inductive, and transient load cause the reactive power U I U I Leading Capacitive Current Lagging Inductive Current Fundamental Reactive Power: Current is leading ¼ of the power cycle relative with the voltage Capacitive 7 Current is lagging ¼ of the power cycle relative with the voltage Inductive

8 What Is Harmonic No-linear device or load cause the harmonic current and voltage ASD (Example of No-linear Load) Current Waveform Current Spectrum Harmonic: 8 Sinusoidal voltages/currents that are integer multiples frequency of the power frequency Described by the complete harmonic spectrum with magnitudes and phase angles

9 Current Power Quality Challenges 10KV Building,IDC Industrial Field Transformer 10/0.4KV 0.4KV HV/MV Power Distribution Main load: Rectifier(VFD,UPS) Motor, Linear PS Power Quality Issue: Harmonic+Reactive, Dynamic Reactive LV distribution Capacitor Plant 0.4KV LV Distribution Cap Cabinet: Can not solve issue But generate new problem Plant Power Distribution Terminal Equipment VFD UPS Motor Control Device

10 Current Power Quality Issues

11 Case Study I:Active Power Filter Solutions in a Copper Metallurgy Company transformer HV I Distribution HV Distribution transformer LV I Distribution Diesel Generator Active Power Filter LV Distribution LV II Distribution Facility Distribution

12 Case Study I:Active Power Filter Solutions in a Copper Metallurgy Company Location Before/After Total Voltage Total Voltage THDV Total Current Total Current THDi PF (V) (%) (A) (%) Before After APF 12

13 Case Study II: Active Power Filter Solutions In a Chemical Factory Current without APF APF Current with APF 13 THD without APF THD with APF

14 Factory Energy Savings Injection Molding Machine Air Compressor Robotics Factory Waste Water Treatment Elevator

15 Injection Molding Machine Solutions

16 Injection Molding Machine Solutions The energy consumption analysis Hybrid Energy Saving System for Injection Molding Machine Human Machine Interface Hybrid Energy Saving System HES System Heating System 35% 10% HES Energy Saving Cooling System 5% 5% 45% Control System Programmable Logic Controllers Temperature Controller Regular Hydraulic System Heating System 10% Regular hydraulic system 80% 5% Cooling System 5% Control System

17 Air Compressor Solutions Human Machine Interface DOP-B Series Cost Analysis for Air Compressor with Drive Energy Saving Energy Cost 30% 47% Procurement Cost 6% 17% Maintenance Cost AC Motor Drive C2000 PLC inside Programmable Logic Control Cost Analysis for Traditional Air Compressor Procurement Cost Maintenance Cost 12% 11% Energy Cost 77%

18 Robotic Arm Solutions General I/O Modules Human Machine Controller Servo Systems 32 Digital I/O D/A Converters Servo Motors Servo Motors

19 Factory Waste Water Treatment/Recycle Solutions Device Net Programmable Logic Controllers Human Machine Interface Ethernet Communication Modules Communication Modules Unmanageable Industrial Ethernet Switch IO Writing IO Writing AC Motor Drives Connection to wastewater treatment equipment Programmable Logic Controllers

20 Elevator Energy Saving Solutions Electricity Energy-saving benefit (a green factory in Taiwan) Estimated power consumption of traditional elevator: 15,209 kwh Elevator power consumption: 9,179 kwh Estimated saved power: 6,030kWh Energy saving: 40% + + Permanent Magnetic Synchronous Motor Integrated Elevator Drive Active Front End

21 Green Factory Applications

22 HVAC Air Conditioner energy saving successful applications Rolled steel production line in Steel mill Dairy Group Project name: HVAC Location: Hubei Finish time: May, 2011 Products: VFD, PLC Project name: Ventilation System Location: Jilin Finish time: Jan, 2010 Products: VFD Chemical fiber factory Pharmaceutical Company Project name: HVAC Location: Jiangsu Finish time: Oct, 2011 Products: VFD, PLC Project name: Ventilation System Location: Jilin Finish time: Mar, 2010 Products: VFD

23 Green Factory Solar Rooftop and EV Carport Kits 1) 63.36kW Rooftop Solar System (12 Strings) 2) 5.76kW Carport Solar System (24 panels, 2 EVCS s, 1 LED) and Electric Transportation

24 Green Factory Smart LED Lighting Retrofit 2x2 40W Troffer (replacing 80W) 2x4 60W Troffer (replacing 160W) 2x4 60W Troffer (replacing 160W) 100W High Bay (replacing 250W) 60W Garage Light

25 Summary Unmanageable Industrial Ethernet Switch Renewable Energy Micro-grid Renewable Energy Micro-grid Energy Management System Unmanageable Industrial Ethernet Switch Industrial Ethernet Switch Human Machine Interface Programmabl e Logic Controller Chiller Programmable Logic Controller AC Motor Drive Cooling Tower Power Quality Management AC Motor Drive Lighting System Web IP Camera Elevator Energy Saving System Pump HVAC System Air Handling Unit Automation System for Factory Production Lines AC Motor and Drive (Applications on Injection Molding Machine, Air Compressor, Pump, Conveyor and Blower)