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首页  >  教育医疗  >  能源管理系统在生物制药行业的应用

能源管理系统在生物制药行业的应用

发布时间:2022-12-02    浏览量:256

摘要:根据生物制品类企业的电力能源使用特点,制定了符合公司实际情况的能源管理系统,介绍了该系统的架构及其在企业的应用情况,提升了公司能源数据的实时监控能力,优化了公司能源分配,降低了公司电力能源消耗,有针对性地解决了公司生产活动中的能源损耗问题。

Abstract: according to the electric energy use characteristics of biological products companies, has established accord with the actual situation of the company energy management system, this paper introduces the architecture of the system and its application in enterprises, improve the company's energy data real-time monitoring ability, optimizing the allocation of the company's energy, electric energy consumption, reduce the company targeted to solve the problem of the energy loss in the company's production activities.

关键词:能源管理;数据分析;电能计量;节能减排

Key words: Energy management;Data analysis;Electric energy metering;Energy conservation and emissions reduction


0引言Introduction

能源是推动人类经济发展的重要物质资料。生物类企业对能源进行科学合理的测量和监控对于其生产的制品质量起关键性作用。生物制药企业在生产制品时要求设备不间断工作,而持续不断地提供能源是实现该条件的基本要求。企业根据生产经营特点,加强能源监管,制定合理的能源管理体系,既可以提升生产效率,又可以降低生产成本,使企业在市场上具备更强的竞争力。

Energy is an important material material to promote the development of human economy. Scientific and effective measurement and monitoring of energy resources plays a key role in the quality of products produced by biological enterprises. Biopharmaceutical companies require equipment to work continuously when producing products, and continuous energy supply is the basic requirement to achieve this condition.According to the characteristics of production and operation, enterprises should strengthen energy supervision and formulate a reasonable energy management system, which can not only improve production efficiency, but also reduce production costs, so that enterprises can have stronger competitiveness in the market.

1企业电力能源消耗简介

Brief introduction of enterprise electric energy consumption

生物医药产业是一个技术含量高、投资高、收入高、风险高的高科技产业。其高科技不仅体现在产品质量的高标准和严格要求上,还体现在对生产设备和生产环境的高要求上。较长的研发周期,高昂的前期成本使其投入大量资金建造符合GMP要求和生物产品标准的清洁工厂和其他公共能源系统设施。

根据我公司年度主要能源消耗统计,总能耗约为两万吨标准煤。根据调查、分析,能源系统全年带负荷运行,能源消耗量随季节、时间出现周期性变化,夏季、冬季电能消耗大,春季、秋季电能消耗量较小;白天能源消耗大,夜晚能源消耗较小,能源运行存在不平衡的特点。

 Biomedicine industry is a high-tech industry with high technology content, high investment, high income and high risk. Its high technology is not only reflected in the high standards and strict requirements of product quality, but also reflected in the high requirements of production equipment and production environment. Long r&d cycles and high upfront costs have led to large investments in clean plants and other public energy system facilities that meet GMP requirements and biological product standards.

According to our company's annual main energy consumption statistics, the total energy consumption is about 20,000 tons of standard coal.According to the investigation and analysis, the energy system operates with load all year round, and the energy consumption changes periodically with season and time. In summer and winter, the energy consumption is large, while in spring and autumn, the energy consumption is small.The energy consumption is large in the day and small at night, and the energy operation is unbalanced.

2电力能源管理系统架构

Architecture of the Electric Energy Management System

能源管理系统是以能源计量、数据传输及分析为一体的实时性管理系统。它依托有线网络通信,实现企业动力系统实时监控、能耗综合统计分析、成本分摊、对高耗能负载设备进行特性分析,实现能源的优化分配,更好地实现节能减排。 

企业能源管理系统由在线监测数据采集系统、能源数据传输系统、能源运行监管系统、能效分析管理系统等构成。

Energy management system is a real-time management system integrating energy measurement, data transmission and analysis.Relying on wired network communication, it can realize real-time monitoring of enterprise power system, comprehensive statistical analysis of energy consumption, cost allocation, and analysis of advanced characteristics of energy-consuming load equipment, so as to realize optimal allocation of energy and achieve better energy conservation and emission reduction. 

The enterprise energy management system consists of online monitoring data acquisition system, energy data transmission system, energy operation supervision system, energy efficiency analysis and management system, etc.

2.1电力能源管理系统功能Power energy management system functions

能源管理系统主要由能源监管、监控和能源信息平台组成。其中能源管理平台由服务器、数据库、智能数据采集器和前置机等设备组成。能源监测系统是对能耗数据进行采集、统计、分析的处理平台。能源信息平台是指由末端能耗仪表组成的采集层网络平台。

The energy management system is mainly composed of energy supervision, monitoring and energy information platform. The energy management platform consists of server, database, intelligent data collector and front-end machine.Energy monitoring system is a processing platform for collecting, counting and analyzing energy consumption data.Energy information platform is a collection layer network platform composed of terminal energy consumption meters.

2.2电力能源采集方式Electric energy collection method

随着我公司一、二、三级能源计量设备的逐步完善,对能源数据的实效性和准确性有了更高的要求,人工抄表方式已不能满足上述要求。为了实现数据实时化、准确化管理,就要采用技术先进、精度高、可靠性好的智能采集设备代替传统人工作业。

我公司供电性质为负荷企业,中心配电室为双回路供电。车间采用电子式电能计量表对电能进行计量,能够提供高精度的三相电压、电流和功率等基本测量数据,具有复费率计算、需量计算、谐波计算等多种功能;采用便于功能扩展的模块化设计和易于读取数据的大屏幕显示。车间根据装配电能表的数量,通过选择16端口、8端口、4端口智能数据采集器来满足需求。采集器作为计量设备与控制主机之间的桥梁,其规约转换功能能够代替前置机选择不同的采集规约,实时采集各种智能设备的数据信息,实现信息的汇总及处理。

With the gradual improvement of the first, second and third level energy metering equipment of our company, there are higher requirements on the effectiveness and accuracy of energy source data, and the manual meter reading method can no longer meet the above requirements.In order to realize real-time and accurate data management, it is necessary to replace traditional manual operation with intelligent acquisition equipment with advanced technology, high precision and good reliability.

The power supply nature of our company is the load enterprise, the central distribution room is the double circuit power supply.The workshop adopts electronic power meter to measure the electric energy, which can provide the basic measurement data of three-phase voltage, current and power with high precision, and has multiple functions such as compound rate calculation, demand calculation, harmonic calculation and so on.Modular design for easy function expansion and large screen display for easy data reading.According to the number of electricity meters assembled, the workshop chooses intelligent data collector with port 16, port 8 and port 4 to meet the requirements.As a bridge between metering equipment and control host, the collector's protocol conversion function can replace the preprocessor to select different acquisition protocols, collect real-time data of various intelligent equipment, and realize information summary and processing.

2.3网络通信功能Network communication function

能源监控系统采用总线、RS485通信线、以太网线、光纤等多种通信方式。该系统可兼容其他通信设备,通过监控大屏实时显示能源系统的运行状态和在线运行参数。根据与项目相关的能源监控需求,每个能源子系统图可以根据需求或实际运行条件进行修改和配置,系统将根据修改后的条件实时反映运行参数。

The energy monitoring system adopts bus, RS485 communication line, ethernet line, optical fiber and other communication modes. The system is compatible with other communication devices, and displays the running status and online running parameters of the energy system by monitoring the large screen.According to the energy monitoring requirements related to the project, each energy subsystem diagram can be modified and configured according to the requirements or actual operating conditions, and the system will reflect the operation parameters in real time according to the modified conditions.

3电力能源管理系统应用Application of electric energy management system

电力能源管理系统向公司局域网发布能源数据,具体指标包括实时监控、统计报告、分析比较、事故报警、目标管理、节能评估等。管理者和技术人员可以在相应权限下读取相关数据。该平台可以充分体现各种功能,界面清晰明了,易于理解,通俗易懂。

The power energy management system releases energy data to the company's LOCAL area network. Specific indicators include real-time monitoring, statistical reporting, analysis and comparison, accident alarm, target management, energy conservation assessment, etc.Managers and technicians can read the relevant data under the appropriate authority.The platform can fully reflect a variety of functions, interface clear, easy to understand, easy to understand.

3.1能源管理系统功能Energy management system functions

3.1.1电能数据采集 Power data acquisition

(1)能耗数据采集方式有智能设备采集和人工抄表两种方式。采集器可独立保存15~30天的历史数据,防止网络中断恢复后的数据补录。

(2)自动采集的智能仪表数据支持RS485、M-BUS或以太网标准接口和标准MODBUS、DLT-645、CJT-188等通信协议,针对采用非标准规约的仪表支持通信接口程序的开发,确保数据的正常采集。

(3)数据自动采集间隔不超过1 min,数据存储间隔可根据实际需求进行灵活设置,存储间隔支持5 min。 

(4)主要采集参数包括三相电压、三相电流、有功功率、无功功率、功率因数、电度等。

(1) There are two ways of energy consumption data collection: intelligent equipment collection and manual meter reading.The collector can save the historical data of 15 ~ 30 days independently to prevent the replacement of data after network interruption and recovery.

(2) Automatic collection of intelligent instrument data support RS485, M-BUS or Ethernet standard interface and standard MODBUS, DLT-645, CJT-188 and other communication protocols, for the use of non-standard protocol instrument support communication interface program development, to ensure the normal data collection.

(3) The interval of automatic data collection is no more than 1 min. The data storage interval can be flexibly set according to actual requirements. The storage interval supports 5 min. 

(4) Main acquisition parameters include three-phase voltage, three-phase current, active power, reactive power, power factor, electric degree, etc.

3.1.2电能数据报表Power data report

(1)系统提供分类、分项、分区域等固定格式的能耗统计日、周、月、季、年报表。 

(2)系统支持创建新的符合管理人员实际管理需求的能耗统计报表。 

(3)所有报表支持手动生成和定期自动生成及邮件分发。 

(4)所有系统报表均可支持办公自动化软件(Excel)。

(1) The system provides daily, weekly, monthly, quarterly and annual reports of energy consumption statistics in fixed formats such as classification, itemization and subdivision. 

(2) The system supports the creation of new energy consumption statistics that meet the actual management needs of managers. 

(3) All reports support manual generation and regular automatic generation and mail distribution. 

(4) All system reports can support office automation software(Excel).

3.1.3设备信息管理Equipment information management

(1)计量仪表信息管理。可灵活定义各采集点计量器具的用能属性、归属关系,系统按照仪表属性自动完成对应能耗数据统计;计量仪表在线状态可视化监视,并实现仪表故障报警;进行仪表数据的完整性统计,当存在数据缺失时,能进行数据合理性评估,并提醒运行人员进行检查和维护;支持仪表内部参数的远程查询与设置,参数包括仪表地址、通信速率、接线模式、CT变比、PT变比等。 

(2)用能设备信息管理。系统可以按照设备用能属性,实现设备的分类管理;可以监控用能设备的运行状态及关键参数,建立设备资产管理和维护管理文件;对设备的历史维护记录和维护计划进行在线管理,使得生产过程安全、稳定。

(1) Metering instrument information management.It can flexibly define the energy use attribute and ownership relationship of measuring instruments at each collection point, and the system can automatically complete the corresponding energy consumption data statistics according to the instrument attributes.Visual monitoring of on-line status of metering instruments, and the realization of instrument fault alarm;Conduct integrity statistics of instrument data, evaluate the validity of data in case of missing data, and remind operators to check and maintain;Supports remote query and setting of internal parameters of the instrument, including instrument address, communication rate, wiring mode, CT variable ratio, PT variable ratio, etc. 

(2) Energy equipment information management.The system can realize the classified management of equipment according to the attribute of equipment energy use.Can monitor the running state and key parameters of energy-using equipment, establish equipment asset management and maintenance management files;Manage the historical maintenance record and maintenance plan of the equipment online to make the production process safe and stable.

3.1.4系统安全管理System safety management

(1)用户管理。系统可以根据需要创建、删除用户,允许管理员负责管理组内用户。 

(2)权限管理。系统登陆需通过用户密码和权限验证,并对所有操作事件进行记录。支持分级授权机制,不同管理权限人员可根据系统设定进行分级访问。

(3)日志管理。系统记录/查询用户的各项操作、报警信息等,记录/查询自身运行过程中的错误、诊断日志信息。

(1) User management.The system can create and delete users as needed, allowing administrators to be responsible for managing users within a group. 

(2) Authority management.The system login needs to be verified by user password and permission, and all operational events are recorded. It supports hierarchical authorization mechanism, and personnel with different administrative authority can access hierarchically according to system Settings.

(3) Log management.The system records/queries the user's various operations, alarm information, etc., and records/queries the error and diagnostic log information in its own operation process.

3.2能源消耗分析与管理Energy consumption analysis and management

根据生物制药企业药品生产质量管理规范,对企业生产所需能源进行能源管理。依据能源平台分析得出的数据对企业生产过程中的能源进行成本分摊,促使各生产车间改进生产工艺和促使高耗能设备设施的更新换代,实现各部门和生产车间能源消耗的标杆管理,科学准确地定义和分析各部门团队的能源消耗成本,方便财务数据核算,将能源成本分摊到各部门,分析各部门的能源消耗情况,分析能源消耗成本影响,维护基础数据等。

According to the drug production quality management standard of bio-pharmaceutical enterprises, the energy needed for production shall be managed.Energy platform based on analysis of the data of the energy in the process of enterprise production cost allocation, promotes each production workshop to improve production technology and promote the upgrading of energy-consuming equipment, realize the departments of energy consumption and production workshop benchmarking, scientific and accurate definition and analysis of the energy consumption cost of each department team, convenient financial data calculation, the energy cost allocation to each department, analysis of energy consumption departments, analyze the effect of energy consumption cost based data maintenance, etc.

4安科瑞工业能耗管理平台介绍Introduction of Acrel industrial energy consumption management platform

4.1平台架构介绍Platform Architecture Introduction

安科瑞能源管控系统采用分层分布式网络结构,具有良好的可靠性与实时性,主要由现场设备层(能源计量终端)、通讯管理层(通讯管理终端)和主站层(能源监控平台)三个部分组成。

以上三个部分分别贯穿整个系统的全部结构。能源管理系统总体设计结构按照能源管理的基本结构设计,满足以上三部分的同时,增加了部分分析、监控、决策和发布平台。

Acrel energy management and control system adopts the layered and distributed network structure, which has good reliability and real-time performance. It is mainly composed of three parts: the field equipment layer (energy metering terminal), the communication management layer (communication management terminal) and the main station layer (energy monitoring platform).

The above three parts run through the whole structure of the system respectively.The overall design structure of the energy management system is designed according to the basic structure of energy management. While meeting the above three parts, part of the analysis, monitoring, decision-making and release platform is added.

图4 工业能耗管理平台架构组成

FIG. 4 Architecture composition of industrial energy consumption management platform

4.2平台功能介绍 Platform function introduction

图5 工业能耗管理功能示意图

FIG. 5 Function diagram of industrial energy consumption management

4.2.1可视化展示 Visual presentation

展示企业各类能耗总量、折标值、能源成本、能源消耗趋势、分项能耗占比、区域能源消耗对比,以及当前天气情况、污染情况,并三维展示企业重要工艺或工段的能源消耗动态。

Display the total amount of energy consumption, discount value, energy cost, energy consumption trend, proportion of energy consumption by item, regional energy consumption comparison, as well as current weather conditions and pollution situation, and display the energy consumption dynamics of important processes or sections of the enterprise in three dimensions.

4.2.2实时监控 Real-time monitoring

对企业各点位的能源使用、报警等情况进行实时的监控。以便企业用户能够实时的监测各个点位的运作情况,同时能更快速的掌握点位的报警。

Real-time monitoring of energy use and alarm at each point of the enterprise.In this way, enterprise users can monitor the operation of each point in real time and grasp the alarm of the point more quickly.

4.2.3用能统计 Energy consumption statistical

从能源使用种类、监测区域、生产工艺/工段时间、分项等维度,采用曲线、饼图、直方图、累积图、数字表等方式对企业用能统计、同比、环比分析、折标对比,找出能源使用过程中的漏洞和不合理地方,从而调整能源 分配策略,减少能源使用过程中的浪费。

From the types of energy use, monitoring area, production process/section time, disciplines such as dimension, use curve, pie charts, histograms, cumulative figure, digital table can use statistics, year-on-year, from analysis of the enterprise, the contrast, find out loopholes in the process of using energy and unreasonable place, so as to adjust the energy allocation strategy, reduce energy waste in the process of use.

4.2.4单耗统计Single consumption statistics

与企业MES系统对接,通过产品产量以及系统采集的能耗数据,在产品单耗中生成产品单耗趋势图,并进行同比和环比分析。以便企业能够根据产品单耗情况来调整生产工艺,从而降低能耗。

Docking with enterprise MES system, through product output and energy consumption data collected by the system, the trend chart of product consumption per unit was generated in the product consumption, and the year-on-year and sequential analysis was carried out.So that the enterprise can adjust the production process according to the product consumption, thus reducing energy consumption.

4.2.5绩效分析Performance Analysis

对各类能源使用、消耗、转换,按班组、区域、产线、工段等进行日、周、月、年、指定时段,结合能源计划或定额制定的绩效指标进行KPI比较考核,帮助企业了解内部能效水平和节能潜力。

The use, consumption and conversion of various types of energy are compared and assessed by KPI according to the performance indicators formulated by energy plan or quota, including day, week, month, year and designated period according to shift group, region, production line and section, so as to help enterprises understand the internal energy efficiency level and energy saving potential.

4.2.6能耗预测Energy consumption prediction

通过对企业生产工艺、生产设备等的能耗使用情况进行分析,建立能耗计算模型,根据人工智能算法对数据和模型进行修正,对未来企业能耗趋势进行预测分析,为节能提供合理的决策依据。

By analyzing the energy consumption of the production process and production equipment of the enterprise, the calculation model of energy consumption is established, the data and model are modified according to the artificial intelligence algorithm, and the future trend of energy consumption of the enterprise is predicted and analyzed, so as to provide an effective decision basis for energy conservation.

4.2.7运行监测Operation monitoring

系统对区域、工段、设备能源消耗进行数据采集,监测设备及工艺运行状态,如温度、湿度、流量、压力、速度等,并支持变配电系统一次运行监视。可直接从动态监测平面图快速浏览到所管理的能耗数据,支持按能源种类、车间、工段、时间等维度查询相关能源用量。

The system collects data on the energy consumption of the region, section and equipment, monitors the operation status of the equipment and process, such as temperature, humidity, flow, pressure, speed, etc., and supports the one-time operation monitoring of the transformer and distribution system.It can browse the managed energy consumption data directly from the dynamic monitoring plan, and can query the relevant energy consumption by energy type, workshop, section, time and other dimensions.

4.2.8分析报告Analysis report

以年、月、日对企业的能源利用情况、线路损耗情况、设备运行情况、运维情况等进行统计分析,让用户了解系统的运行情况,并为用户提供数据基础,方便用户发现设备异常,从而找出改良点,以及针对用能情况挖掘节能潜力。

Year, month, day of enterprise energy utilization, line loss situation, the equipment running status, operational conditions, such as statistical analysis, let users understand the operation of system, and provide data for the user base, and easy to find equipment is unusual, to find out the improvement points, and can use of mining and energy saving potential.

4.2.9移动端支持Mobile terminal support

APP支持Android、IOS操作系统,方便用户按能源分类、区域、车间、工序、班组、设备等不同维度掌握企业能源消耗、效率分析、同环比分析、能耗折标、用能预测、运行监视、异常报警等。

The APP supports Android and IOS operating systems, making it easy for users to grasp the enterprise's energy consumption, efficiency analysis, quarter-on-quarter analysis, energy consumption folding, energy use prediction, operation monitoring, abnormal alarm, etc. according to different dimensions such as energy classification, region, workshop, process, team, equipment, etc.

4.3工业能耗平台设备选型Equipment selection for industrial energy consumption platform


表1 工业能耗管理设备选型表


Table 1 Industrial energy consumption management equipment selection table

5结束语Conclusion

使用、开发公司能源管理系统,可弥补生物制药企业在能源管理方面的短板,应用数字化的能源信息,方便管理者直观读取企业能源消耗情况。相较于以往人工抄表的方式,自动化、实时化、智能化的能源管理系统很大地提高了工作效率,也为后期准确化能源数据统计、分析及记录提供条件。

The use and development of the company's energy management system can make up for the shortcomings of bio-pharmaceutical enterprises in energy management, and the application of digital energy information can facilitate managers to read the enterprise's energy consumption directly.Compared with the previous manual meter reading method, the automatic, real-time and intelligent energy management system greatly improves the work efficiency, and also provides conditions for accurate energy data statistics, analysis and recording in the later stage.

5.1系统运行连续、可靠、安全 The system runs continuously, reliably and safely

能源管理系统根据生物制药企业的能源使用特点,对系统功能做出相应改进。系统可连续可靠地对公司能耗指标进行评估、匹配,加强对关键能耗数据及能耗设备的监控。

The energy management system improves the function of the system according to the energy use characteristics of bio-pharmaceutical enterprises.The system can continuously and reliably evaluate and match the company's energy consumption indicators, and strengthen the monitoring of key energy consumption data and energy consumption equipment. 

5.2系统操作使用简便 The system is easy to operate and use

从能源管理人员的分析和总结到相关领导的审核和批准,从部门能源管理到企业能源总结和报告,整个工作流程清晰易懂,符合整体能源管理要求和企业能源管理标准。 

From the analysis and summary of energy management personnel to the review and approval of relevant leaders, from departmental energy management to enterprise energy summary and report, the whole work process is clear and easy to understand, in line with the overall energy management requirements and enterprise energy management standards.

5.3系统监管简洁合理 System supervision is simple and effective

该系统根据EMS模式进行能源数据管理,使得系统运行简洁,对分散能源数据进行集中化管理控制。根据数据分析结果提出相对应的解决方法,实现企业制定的能源节约目标。 

This system carries on the energy data management according to the EMS mode, causes the system operation to be concise, carries on the centralized management control to the decentralized energy data.According to the data analysis results, the corresponding solutions are proposed to achieve the energy conservation targets set by the enterprise. 

5.4实现精细化管理 Implementation of fine management

通过能源管理系统的自动化数据信息采集,很大地提升了数据的实时性和准确性,实现能源精细化管理。

Through the automatic data collection of the energy management system, the real-time and accuracy of the data are greatly improved, and the refined energy management is realized.

                              

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