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FACTAUNIVERSITATIS(NIˇS)SER.:ELEC.ENERG.vol.22,no.3,December2009,329-339AutomaticControlofIndustrialPeakLoadsMarijaKacarska,VesnaArnautovski-ToˇsevaandSanjaVelevaAbstract:Automaticcontrolofequipmentisanticipatedtorepresentthenextlog-icalstepintheprogressionfrompassivemonitoringtowardplantwideautomation.Automatictransferfunctions,load-sheddingandloadsequencingareexpectedtofindincreasingapplication.InthispaperadevicenamedPeakLoadformonitoringandcontrolofpowerconsumptioninindustrialplantsispresented.ItisaPLCbasedmaxigraphdevelopedupontheanalysisofefficientandoptimizeduseoftheelectricalenergyandisplannedtobeusedbymediumandbigindustrialenergyconsumerswithpurposetodecreasethecostoftheirproduction.Keywords:Controlling,energyefficiency,load-shedding.1IntroductionINordertocontrolenergycosts,theplantengineerneedstobeawarewhenen-ergyandpowerarebeingconsumedandbywhom.Byimportingenergyandpowerdataintoastandardspreadsheet,energyandpowerusagecanbetrackedbytimeofdayandcostsallocatedbacktoresponsibledepartments.Costsarethenre-ducedeitherthroughcarefulreductionofindividualconsumptionorbyreschedul-ingenergy-intensiveoperationsfrompeaktimestooff-peaktimes.Inmanycases,thedemandchargeisbasedonasinglepeakloadinglevelsetbytheindustrialplant.Theplantpaysdemandchargesbasedonthislevel,evenduringsubsequentmonthswhenactualpowerconsumptionmaybefarless.Toreducedemandcharges,theindustrialplant’saveragepowerconsumptionforeachdemandperiod(usually15or30minuteintervals)isloggedtoaspreadsheet.DemandManuscriptreceivedonNovember15,2009.Anearlierversionofthispaperwaspresentedatthe9thInternationalConferenceonAppliedElectromagenticsPES2009,August30-September2,2009,Nis,Serbia.M.Kacarska,V.Arnautovski-ToˇsevaandS.VelevaarewithFacultyofElectricalEn-gineeringandInformationalTechnologies,Karpos2b.b.,Skopje,[e-mail],V.Arnautovski-ToˇsevaandS.Veleva:plotsaregeneratedfromthesedata.Bybalancingtheloadsandspreadingpower-consumptionlevelsmoreevenlyacrossdemandperiods,dramaticsavingscanbeachieved.Newpowerequipmentassembliessuchaslow-voltageandmedium-voltageswitchgear,switchboards,andmotorcontrolcentrescanbesuppliedwithmoni-toringequipmenttoprovideremoteaccessofpowersysteminformation.Inaddi-tion,thisequipmentcanbeaugmentedtoperformvariousautomaticcontrolfunc-tionsandprovideelaboratelocaldisplayofsystemconditionsinthepowerequip-ment[1].Inordertomakeanappropriatedesignofthesystemformonitoringandcontrolofthepowerloads,itisnecessarytoprovidethefollowingdata:Electricitybillspaidbytheconsumer(largeindustries)foratleastonewholeyear;andGraphicalpresentationofdataofelectricpower,measured(withthecontroller)forcertainperiodoftimewhentheindustryworkswithfullcapacity.Activeandreactivepowerdataarecommondataforanalysisofenergyeffi-ciencyevents[2].Thecollecteddataareusedtoforecasttheactivepowerinaperiodof15minutesbyperformingthefollowingtasks:•Iftheforecastedactivepowerisabovethelimits,themachinesandapparatuswillbecutoffinaccordancetothepreviouslyagreedprioritylist,or•Iftheforecastedactivepowerisbelowthelimits,thepowersupplyforma-chinesandapparatuswillbeswitchonwithrespecttothepreviouslyagreedprioritylist.Theswitchingonandoffofmachinesandapparatuswillbedecidedbythelocaloperators,or,asproposedinthispaper,automaticallybycontrolsystem.ThedevicenamedPeakLoad,proposedinthispaper,integratesmonitoring,controllingandoptimizingfunctions,relatedtothepowerandenergyconsumptionofindustrialconsumersinordertoreducetheoperatingcosts.IthasbeendevelopedbytheteamofresearchersatFacultyofElectricalEngineeringandInformationTechnologiesinSkopjeandmanufacturedincooperationwithcompanySIMT-Skopje.ThedeviceisanewproductmanufacturedbylocalSME.Thenewdeviceisplanedtobeusedbymediumandbigindustrialenergycon-sumers,i.e.factoriesandplants,withpurposetomonitor,analyzeandoptimizetheirelectricalenergyconsumption.2ThepeakloaddeviceThePeakLoadisanintelligentmaxgraphthatanalyzesthecurrentstateoftheuser’ssystem(thedevicesandmachinesconnectedtoit)andcontrolsthepowerconsump-AutomaticControlofIndustrial...331tion.Itisapeakloadcontrollerwhichprovidesoptimizedandefficientuseofelec-tricalenergybasedontheneedsoftheusers.Theusercandefinethemaximumandminimumpowerconsumptionaswellaspriorityofworkoftheconnecteddevices.Accordingtomeasuredpowertheindustryloadswillbeconnectedordisconnectedbythecontroller.Thatwaytheuserhasapowerfultooltocontrolthepowercon-sumptionandreducetheexpensesforit.Thiscontrollerservesasthepowerfactorcorrectioncontrollerandpeakloadcontroller.Thedeviceiscomposedoftwoparts:hardwareandsoftware.Thehardwarepartisthecontrolleritself.Thesoftwarepartconsistsoftwoprograms.ThefirstonerunsonthePLCandthesecondonerunsonthecomputer.Theseprogramsprovideconfigurationoftheprocessparameters,supervisionoftheprocessandalarming.Graphicaluserinterface(GUI)providesafriendlyuserinterfacesforapplica-tionprogramssuchas:load-shedding,power-qualitycontroletc.[3].2.1PrincipleofworkInputmeasurementsofthemaxigrapharethetotalpowerconsumptionofallma-chinesandthemachine’sdemandswhenturnedon.Asanoutpu