EP1631936A1 - Method for increasing the capacity of an installation used to carry out an industrial process - Google Patents
Method for increasing the capacity of an installation used to carry out an industrial processInfo
- Publication number
- EP1631936A1 EP1631936A1 EP04736391A EP04736391A EP1631936A1 EP 1631936 A1 EP1631936 A1 EP 1631936A1 EP 04736391 A EP04736391 A EP 04736391A EP 04736391 A EP04736391 A EP 04736391A EP 1631936 A1 EP1631936 A1 EP 1631936A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- performance
- control
- plant
- control loops
- process variables
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000000034 method Methods 0.000 title claims abstract description 93
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- 238000009434 installation Methods 0.000 title abstract 5
- 239000000123 paper Substances 0.000 claims description 23
- 238000010924 continuous production Methods 0.000 claims description 4
- 238000001514 detection method Methods 0.000 claims description 4
- 238000011161 development Methods 0.000 claims description 3
- 239000011888 foil Substances 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 239000004753 textile Substances 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 238000011156 evaluation Methods 0.000 description 4
- 238000011835 investigation Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 230000007774 longterm Effects 0.000 description 3
- 239000000835 fiber Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000002918 waste heat Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000109 continuous material Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000013144 data compression Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000010079 rubber tapping Methods 0.000 description 1
- 230000009897 systematic effect Effects 0.000 description 1
Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
- H02H3/006—Calibration or setting of parameters
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H2239/00—Miscellaneous
- H01H2239/078—Variable resistance by variable contact area or point
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
- H02H3/08—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H3/00—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection
- H02H3/08—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current
- H02H3/087—Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal electric working condition with or without subsequent reconnection ; integrated protection responsive to excess current for DC applications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
- H02H7/26—Sectionalised protection of cable or line systems, e.g. for disconnecting a section on which a short-circuit, earth fault, or arc discharge has occured
- H02H7/268—Sectionalised protection of cable or line systems, e.g. for disconnecting a section on which a short-circuit, earth fault, or arc discharge has occured for DC systems
Definitions
- the invention relates to a method for increasing the performance of a plant for carrying out an industrial process.
- Such an industrial process can be a process with continuous material webs such as in the production of paper, textiles, plastic or metal foils.
- the performance of the process is determined by the speed of the web, e.g. measured in meters per second.
- the invention is based on the knowledge that previous measures for increasing the performance in the plants were always based on selective considerations of the plant and therefore generally lack long-term sustainability. Based on the determination of the process variables relevant to the performance of the system and their detection under changing operating conditions, a comprehensive consideration of the influencing factors limiting the performance of the system is ensured. Under changing operating conditions, the operating conditions that occur during regular operation of the system, i.e. e.g. in the case of a paper machine, the operation of the machine with paper of different qualities and types is understood. It is thus avoided that only some aspects of the system, such as the drive system are considered under some special operating conditions, but other factors and operating conditions that are decisive for performance are not taken into account. As a result, not only a short-term, but a sustainable increase in performance is possible.
- the lowest control reserve of the control loops determines the increase in performance that can be achieved without further measures. This ensures that the development of existing power reserves is checked first and that these reserves are tapped if necessary. This puts the under economic The most achievable increase in performance.
- control loops with too little control reserve already shows the effort that will be required for further investigations and possibly also for the implementation of measures to increase performance.
- a decision is made to define a lower increase in output so that further investigations are only necessary for the correspondingly smaller number of control loops.
- a technical and / or technological control loops with insufficient Rege 'lreser- ve and Development of measures to prepare the respective necessary control reserves by relieving the respective control circuits and / or by replacing components is carried out in subsequent steps Examine in the respective control loops through more powerful components.
- the method according to the invention is particularly advantageously suitable for increasing the performance in a system for executing a continuous process, in particular a process for producing continuous webs of material, e.g. Paper, textiles, plastic or metal foils, the performance of which is determined by the speed of the web.
- a process for producing continuous webs of material e.g. Paper, textiles, plastic or metal foils, the performance of which is determined by the speed of the web.
- 5 shows a machine speed / torque diagram for determining the control reserve in a drive motor and 6 shows a determination of the control reserve in the drive motor of FIG. 5.
- Appendix 1 shows a system 1 for the production of paper.
- Appendix 1 includes a wide variety of system parts that are required for the various steps in the paper manufacturing process, e.g. a stock preparation la, a paper machine lb, rewinder / calender lc, slitter ld and cross cutter le.
- the paper passes through 8 essential parts of the system 1 as a web.
- the system 1 has a multiplicity of drive components 11, automation components 12 and energy supply components 13 for the drive, the power supply and the control or regulation of the various components in the manufacturing process.
- a device 2 is used to determine the control reserves in the system 1.
- the device 2 has a detection unit 3, an evaluation unit 4, an input unit 7 and an output unit 5.
- the detection unit 3 is used to detect process variables P1 ... P10 of the paper manufacturing process on the system 1.
- the process variables can come from a wide variety of sources of the process and can be in any, also different, form, for example analog, binary, numerical and / or as a variable physical variable.
- the evaluation unit 4 serves to determine the control reserves in the control loops of the system 1. For this purpose, a large number of performance characteristics for a large number of components occurring in systems, in particular right of standard components. With the help of the output unit 5, the control reserves can be displayed. Furthermore, the device 2 has an input unit 7 for inputting a desired increase in output in the system 1.
- the method according to the invention is explained in FIG. 2 using a flow chart.
- the method is advantageously carried out by a service provider who has the appropriate know-how and technical options for carrying it out.
- a first step 31 - as explained in detail in FIGS. 3 and 4 - the process variables relevant to the performance of the system are determined.
- these process variables are recorded under changing operating conditions of the system and in a third step 33 - as explained by way of example in FIGS. 5 and 6 - a minimum control reserve of the control loops of the system is determined on the basis of the recorded process variables.
- This control reserve can be used to increase the performance of the system without any significant investment.
- a step 33a it is therefore checked whether an increase in power beyond this lowest control reserve is desired. If this is not the case, the method can be ended in a method step 39b by tapping into the existing power reserves.
- a further increase in output is desired in the system, such a desired increase in output of the system can be defined in a further method step 34.
- the control reserves required for the desired increase in power are determined in the control loops of the system, and in a further method step 36 the control loops are determined with a control reserve that is too low for the desired increase in power.
- technical and / or technological investigations of the control loops can be carried out in a further method step 37 and measures can be developed to produce the respectively required control reserves by relieving the respective control loops and / or by replacing components in the respective control loops with more powerful components become.
- a technical and / or business assessment can be carried out for these measures, on the basis of which the measures in step 39a are finally implemented.
- a process variable representing the performance of the plant is determined in a first step.
- a process variable representing the performance of the plant is determined in a first step.
- a paper manufacturing plant e.g. the speed of the paper in the system.
- a core process 6 of the system is defined and all interfaces 21-25 of the core process 6 to the secondary processes 41-45 surrounding it (for example secondary processes for the supply of energy, water and compressed air). determined and examined for correlations with this representative process variable. This can be done by measuring the physical effects (e.g. forces, currents, fields, flow rates, pressures) at these interfaces. The measurement of these physical effects or process variables can be provided by existing and / or additional ones
- the sub-process running on the paper machine can be defined as the core process. Interfaces to secondary processes with interdependencies with the speed of the paper passing through are then found primarily in the area of material and energy flows, for example in the supply of energy, steam, water, fibers, chemicals and additives as well as the removal of water, condensate and waste heat.
- the relevant process variables in the area of secondary processes are - as shown in FIG.
- the energy supply 51 (measured, for example, as power P), the steam supply 52 (measured as volume per unit of time), the water supply 53 (measured as Volume per unit time), the fiber supply 54 (measured as mass per unit time), the chemical supply 55 (measured as mass per unit time), the water discharge 56 (measured as volume per unit time), the condensate discharge 57 (measured as unit volume per unit time) and the Waste heat removal 58 (measured as power P).
- FIG. 6 shows the torque M of the motor over the speed v of the machine, these two parameters being shown by a linear relationship in accordance with FIG. represents through the line G, are approximated.
- the maximum power of a motor or converter (whichever is lower) is a hyperbolic curve HK in the speed / load level v / M.
- the distance RV of this hyperbolic curve HK to the straight line G is a measure of the control reserve and thus of the maximum possible speed increase.
- control reserve e.g. With regard to the positioning of a vacuum or steam control valve, speed and load of an auxiliary drive, of liquid flows etc., the machine speed can also be plotted instead of over the load over the position of the valve, the speed of the auxiliary drive or the liquid flow, the residence time determined and approximated linear or more complex relationship with the velocity v can be determined.
- processes to be considered are usually not very dynamic.
- the dynamic components in the process variables are not of primary interest even for the determination of the control reserves. Rather, the average long-term behavior of the process variables is of greater interest.
- the process variables are therefore preferably filtered (approx. 2 s) and only sampled approx. Every 5s.
- An online evaluation of the recorded data with subsequent data compression is preferably carried out for a subsequent offline evaluation of the recorded data.
Landscapes
- Paper (AREA)
- Fuses (AREA)
- General Factory Administration (AREA)
- Feedback Control In General (AREA)
Abstract
Description
Beschreibungdescription
Verfahren zur Erhöhung der Leistungsfähigkeit einer Anlage zur Ausführung eines industriellen ProzessesProcess for increasing the performance of a plant for carrying out an industrial process
Die Erfindung bezieht sich auf ein Verfahren zur Erhöhung der Leistungsfähigkeit einer Anlage zur Ausführung eines industriellen Prozesses.The invention relates to a method for increasing the performance of a plant for carrying out an industrial process.
Eine Leistungserhöhung einer Anlage zur Ausführung eines industriellen Prozesses um wenige Prozentpunkte führt in der Regel zu einer überproportional hohen Steigerung des Ertrages für den Betreiber der Anlage. Beispielsweise kann es sich bei einem solchen industriellen Prozesses um einen Prozess mit durchlaufenden Warenbahnen wie bei der Herstellung von Papier, Textilien, Kunststoff- oder Metallfolien handeln. Bei solchen Prozesses wird die Leistungsfähigkeit des Prozesses durch die Geschwindigkeit der Warenbahn, z.B. gemessen in Metern pro Sekunde, bestimmt.An increase in the performance of a plant for the execution of an industrial process by a few percentage points generally leads to a disproportionately high increase in the yield for the operator of the plant. For example, such an industrial process can be a process with continuous material webs such as in the production of paper, textiles, plastic or metal foils. In such processes, the performance of the process is determined by the speed of the web, e.g. measured in meters per second.
Wenn ein Maschinenteil für eine in der Anlage enthaltene Maschine oder ein komplettes Anlagenteil für eine solche Anlage ausgelegt wird, erfolgt dies meistens auf der Basis ähnlicher Maschinen oder Anlagenteile unter Berücksichtigung einiger Leistungsreserven. Unter den in der Anlage vorliegenden Betriebsbedingungen sind die Belastungen der Maschine oder des Anlagenteils allerdings meist unterschiedlich zu den in den bisher bekannten, ähnlichen Anlagen. Es ist somit nicht möglich, eine sichere Aussage darüber zu treffen, welche Leis- tungserhöhung in der Anlage möglich ist, ohne ein oder mehrere Teile der Anlage zu überlasten.If a machine part is designed for a machine contained in the system or a complete system part for such a system, this is usually done on the basis of similar machines or system parts, taking into account some performance reserves. Under the operating conditions in the system, however, the loads on the machine or system part are usually different from those in the previously known, similar systems. It is therefore not possible to make a reliable statement about which increase in output in the system is possible without overloading one or more parts of the system.
Bisher entbehren Maßnahmen zur Leistungserhöhung in solchen Anlagen, insbesondere in komplexen Anlagen wie z.B. Anlagen zur Ausführung kontinuierlicher Prozesse zur Herstellung von Warenbahnen, zudem in der Regel einer langfristigen Nachhaltigkeit. Es ist deshalb Aufgabe vorliegender Erfindung, ein Verfahren anzugeben, welches eine nachhaltige und wirtschaftliche Erhöhung der Leistungsfähigkeit einer Anlage ermöglicht.So far, measures to increase performance in such systems, especially in complex systems such as systems for the execution of continuous processes for the production of webs, have generally been long-term sustainability. It is therefore an object of the present invention to provide a method which enables a sustainable and economical increase in the performance of a system.
Die Lösung dieser Aufgabe gelingt erfindungsgemäß durch ein Verfahren gemäß Patentanspruch 1. Vorteilhafte Ausgestaltungen des Verfahrens sind jeweils Gegenstand der Unteransprüche 2 bis 9.This object is achieved according to the invention by a method according to claim 1. Advantageous embodiments of the method are the subject matter of subclaims 2 to 9.
Die Erfindung geht hierbei von der Erkenntnis aus, dass bisherige Maßnahmen zur Leistungserhöhung in den Anlagen immer nur auf punktuellen Betrachtungen der Anlage beruhten und deshalb in der Regel einer langfristigen Nachhaltigkeit ent- behrten. Aufgrund der erfindungsgemäß vorgesehene Ermittlung der für die Leistungsfähigkeit der Anlage relevanten Prozessgrößen und deren Erfassung bei wechselnden Betriebsbedingungen ist eine umfassende Berücksichtigung der die Leistung der Anlage begrenzenden Einflussfaktoren gewährleistet. Unter wechselnden Betriebsbedingungen werden hierbei die im regulären Betrieb der Anlage vorkommender Betriebsbedingungen, d.h. z.B. im Fall einer Papiermaschine der Betrieb der Maschine bei Papier unterschiedlicher Qualitäten und Sorten, verstanden. Es wird somit vermieden, dass nur punktuell einige As- pekte der Anlage, wie z.B. das Antriebssystem, unter einigen speziellen Betriebsbedingungen betrachtet werden, dagegen andere für die Leistungsfähigkeit maßgebende Faktoren und Betriebsbedingungen aber nicht berücksichtigt werden. Als Ergebnis ist hierdurch nicht nur eine kurzfristige, sondern ei- ne nachhaltige Erhöhung der Leistungsfähigkeit möglich.The invention is based on the knowledge that previous measures for increasing the performance in the plants were always based on selective considerations of the plant and therefore generally lack long-term sustainability. Based on the determination of the process variables relevant to the performance of the system and their detection under changing operating conditions, a comprehensive consideration of the influencing factors limiting the performance of the system is ensured. Under changing operating conditions, the operating conditions that occur during regular operation of the system, i.e. e.g. in the case of a paper machine, the operation of the machine with paper of different qualities and types is understood. It is thus avoided that only some aspects of the system, such as the drive system are considered under some special operating conditions, but other factors and operating conditions that are decisive for performance are not taken into account. As a result, not only a short-term, but a sustainable increase in performance is possible.
Die geringste Regelreserve der Regelkreise bestimmt die ohne weitere Maßnahmen erreichbare Leistungserhöhung. Es ist somit gewährleistet, dass zuerst die Erschließung der vorhandenen Leistungsreserven überprüft und diese Reserven gegebenenfalls erschlossen werden. Dies stellt die unter wirtschaftlichen Gesichtspunkten am günstigsten erreichbare Leistungserhöhung dar.The lowest control reserve of the control loops determines the increase in performance that can be achieved without further measures. This ensures that the development of existing power reserves is checked first and that these reserves are tapped if necessary. This puts the under economic The most achievable increase in performance.
Falls mit zusätzlichen Maßnahmen eine über die vorhandene Leistungsreserve hinausgehende Leistungserhöhung angestrebt wird, kann dies dadurch erfolgen, dass eine angestrebte Leistungserhöhung der Anlage definiert wird, die für die angestrebte Leistungserhöhung notwendigen Regelreserven in den Regelkreisen der Anlage bestimmt werden und die Regelkreise mit einer für die angestrebte Leistungserhöhung zu geringen Regelreserve ermittelt werden.If, with additional measures, an increase in performance beyond the existing power reserve is sought, this can be done by defining a desired increase in performance of the system, determining the control reserves required for the desired increase in performance in the control loops of the system and the control loops with one for the desired Increase in performance can be determined at low control reserve.
Aus der Anzahl der Regelkreise mit zu geringer Regelreserve ist bereits ersichtlich, welcher Aufwand für weitere Untersu- chungen und möglicherweise auch für die Implementierung von Maßnahmen zur Leistungserhöhung notwendig sein wird. Bei einer hohen Anzahl von Regelkreisen kann u.U. entschieden werden, eine geringere Leistungserhöhung zu definieren, so dass nur für die entsprechend geringere Anzahl von Regelkreisen die weitere Untersuchungen notwendig sind.The number of control loops with too little control reserve already shows the effort that will be required for further investigations and possibly also for the implementation of measures to increase performance. With a large number of control loops, a decision is made to define a lower increase in output so that further investigations are only necessary for the correspondingly smaller number of control loops.
Gemäß einer vorteilhaften Ausgestaltung der Erfindung erfolgt in weiteren Schritten ein technisches und/oder technologisches Untersuchen der Regelkreise mit zu geringer Rege'lreser- ve und ein Erarbeiten von Maßnahmen zur Herstellung der jeweilig benötigten Regelreserven durch Entlastung der jeweiligen Regelkreise und/oder durch Ersetzen von Komponenten in den jeweiligen Regelkreisen durch leistungsfähigere Komponenten.According to an advantageous embodiment of the invention, a technical and / or technological control loops with insufficient Rege 'lreser- ve and Development of measures to prepare the respective necessary control reserves by relieving the respective control circuits and / or by replacing components is carried out in subsequent steps Examine in the respective control loops through more powerful components.
Diese Maßnahmen können abschließend technisch und/oder betriebswirtschaftlich bewertet werden. Anhand dieser Bewertung kann der Entscheidungsprozess für die Implementierung der Verbesserungsmaßnahmen vereinfacht und eine unter Kos- ten/Nutzen-Gesichtspunkten optimale Lösung für den Betreiber der Anlage gefunden werden. Insgesamt stellt die Abfolge der vorgenannten Schritte sicher, dass die Punkte vorrangig behandelt werden, bei denen das höchste Verbesserungspotential besteht bzw. die Wirtschaftlichkeit einer Umsetzung am höchsten ist. Zugleich er- laubt diese Vorgehen die wirtschaftliche Erschließung vorhandener Leistungsreserven auch bei hoher Komplexität einer Anlage.These measures can then be technically and / or economically evaluated. On the basis of this assessment, the decision-making process for the implementation of the improvement measures can be simplified and an optimal solution for the operator of the plant can be found from a cost / benefit point of view. Overall, the sequence of the above-mentioned steps ensures that priority is given to the points where there is the greatest potential for improvement or the most economical implementation. At the same time, this procedure enables the economic exploitation of existing power reserves, even when a plant is highly complex.
Das erfindungsgemäße Verfahren eignet sich besonders vorteil- haft zur Erhöhung der Leistungsfähigkeit bei einer Anlage zur Ausführung eines kontinuierlichen Prozesses, insbesondere eines Prozesses zu Herstellung von durchlaufenden Warenbahnen, z.B. Papier, Textilien, Kunststoff- oder Metallfolien, deren Leistungsfähigkeit durch die Geschwindigkeit der Warenbahn bestimmt wird.The method according to the invention is particularly advantageously suitable for increasing the performance in a system for executing a continuous process, in particular a process for producing continuous webs of material, e.g. Paper, textiles, plastic or metal foils, the performance of which is determined by the speed of the web.
Die Erfindung sowie weitere vorteilhafte Ausgestaltungen der Erfindung gemäß den Merkmalen der Unteransprüche werden im folgenden anhand von Ausführungsbeispielen in den Figuren nä- her erläutert. Darin zeigen:The invention and further advantageous embodiments of the invention according to the features of the subclaims are explained in more detail below with reference to exemplary embodiments in the figures. In it show:
FIG 1 eine Erfassung von Prozessgrößen bei einer Anlage zur Papierherstellung,1 shows an acquisition of process variables in a plant for paper production,
FIG 2 eine Darstellung eines erfindungsgemäßen Verfahrensablaufes anhand eines Ablaufdiagramms,2 shows an illustration of a method sequence according to the invention using a flow diagram,
FIG 3 eine prinzipielle Darstellung zur Ermittlung der für die Leistungsfähigkeit einer Anlage relevanten Prozessgrößen,3 shows a basic illustration for determining the process variables relevant for the performance of a system,
FIG 4 eine Darstellung der relevanten Prozessgrößen bei einer Papiermaschine,4 shows a representation of the relevant process variables in a paper machine,
FIG 5 ein Maschinengeschwindigkeit/Drehmoment-Diagramm für die Bestimmung der Regelreserve bei einem Antriebsmotor und FIG 6 eine Bestimmung der Regelreserve bei dem Antriebsmotor der FIG 5.5 shows a machine speed / torque diagram for determining the control reserve in a drive motor and 6 shows a determination of the control reserve in the drive motor of FIG. 5.
Die FIG 1 zeigt eine Anlage 1 zur Herstellung von Papier. Die Anlage 1 umfasst verschiedenste Anlagenteile, die für die verschiedenen Schritte im Herstellungsprozess für Papier benötigt werden , so z.B. eine Stoffaufbereitung la, eine Papiermaschine lb, Umroller/Kalander lc, Rollenschneider ld und Querschneider le. Das Papier durchläuft als Warenbahn 8 wesentliche Teile der Anlage 1.1 shows a system 1 for the production of paper. Appendix 1 includes a wide variety of system parts that are required for the various steps in the paper manufacturing process, e.g. a stock preparation la, a paper machine lb, rewinder / calender lc, slitter ld and cross cutter le. The paper passes through 8 essential parts of the system 1 as a web.
Die Anlage 1 weist für den Antrieb, die Stromversorgung und der Steuerung bzw. Regelung der verschiedenen Komponenten im Herstellungsprozess eine Vielzahl von Antriebskomponenten 11, Automatisierungskomponenten 12 und Energieversorgungskomponenten 13 auf.The system 1 has a multiplicity of drive components 11, automation components 12 and energy supply components 13 for the drive, the power supply and the control or regulation of the various components in the manufacturing process.
Eine Vorrichtung 2 dient zur Ermittlung der Regelreserven in der Anlage 1. Die Vorrichtung 2 weist eine Erfassungseinheit 3, eine Auswerteeinheit 4, eine Eingabeeinheit 7 und eine Ausgabeeinheit 5 auf.A device 2 is used to determine the control reserves in the system 1. The device 2 has a detection unit 3, an evaluation unit 4, an input unit 7 and an output unit 5.
Die Erfassungseinheit 3 dient zur Erfassung von Prozessgrößen P1...P10 des Papierherstellungsprozesses auf der Anlage 1.The detection unit 3 is used to detect process variables P1 ... P10 of the paper manufacturing process on the system 1.
Dabei kann es sich z.B. um Messsignale handeln, die mit Hilfe von in der Anlage 1 bereits vorhandenen und/oder vorzusehenden Signalgebern erfasst werden.It can e.g. are measurement signals which are detected with the aid of signal transmitters which are already present and / or to be provided in Appendix 1.
Die Prozessgrößen können aus verschiedensten Quellen des Prozesses stammen und in beliebiger, auch unterschiedlicher Form, z.B. analog, binär, numerisch und/oder als veränderliche physikalische Größe vorliegen. Die Auswerteeinheit 4 dient zur Bestimmung der Regelreserven in den Regelkreisen der Anlage 1. Hierzu sind in einem Speicher der Auswerteeinheit 4 ein große Anzahl von Leistungskennlinien für eine Vielzahl von in Anlagen vorkommenden Komponenten, insbesonde- re von Standardkomponenten, hinterlegt. Mit Hilfe der Ausgabeeinheit 5 können die Regelreserven zur Anzeige gebracht werden. Ferner weist die Vorrichtung 2 eine Eingabeeinheit 7 zur Eingabe einer angestrebten Leistungserhöhung in der Anla- ge 1 auf.The process variables can come from a wide variety of sources of the process and can be in any, also different, form, for example analog, binary, numerical and / or as a variable physical variable. The evaluation unit 4 serves to determine the control reserves in the control loops of the system 1. For this purpose, a large number of performance characteristics for a large number of components occurring in systems, in particular right of standard components. With the help of the output unit 5, the control reserves can be displayed. Furthermore, the device 2 has an input unit 7 for inputting a desired increase in output in the system 1.
In FIG 2 wird das erfindungsgemäße Verfahren anhand eines Ablaufdiagramms erläutert. Das Verfahren wird vorteilhafterweise von einem Dienstleistungsanbieter durchgeführt, der ent- sprechendes Know-How und technische Möglichkeiten zu dessen Durchführung aufweist.The method according to the invention is explained in FIG. 2 using a flow chart. The method is advantageously carried out by a service provider who has the appropriate know-how and technical options for carrying it out.
In einem ersten Schritt 31 werden - wie im Detail in FIG 3 und 4 erläutert - die für die Leistungsfähigkeit der Anlage relevanten Prozessgrößen ermittelt. In einem zweiten Schritt 32 werden diese Prozessgrößen unter wechselnden Betriebsbedingungen der Anlage erfasst und in einem dritten Schritt 33 - wie beispielhaft in FIG 5 und 6 erläutert - eine geringste Regelreserve der Regelkreise der Anlage anhand der erfassten Prozessgrößen ermittelt. Diese Regelreserve kann zur Erhöhung der Leistungsfähigkeit der Anlage ohne nennenswerten Investitionsaufwand genutzt werden. In einem Schritt 33a wird deshalb geprüft, ob eine über diese geringste Regelreserve hinausgehende Leistungserhöhung gewünscht ist. Ist dies nicht der Fall, kann in einem Verfahrensschritt 39b durch Erschließung der vorhandenen Leistungsreserven das Verfahren beendet werden.In a first step 31 - as explained in detail in FIGS. 3 and 4 - the process variables relevant to the performance of the system are determined. In a second step 32, these process variables are recorded under changing operating conditions of the system and in a third step 33 - as explained by way of example in FIGS. 5 and 6 - a minimum control reserve of the control loops of the system is determined on the basis of the recorded process variables. This control reserve can be used to increase the performance of the system without any significant investment. In a step 33a it is therefore checked whether an increase in power beyond this lowest control reserve is desired. If this is not the case, the method can be ended in a method step 39b by tapping into the existing power reserves.
Falls eine darüber hinaus gehende Leistungserhöhung in der Anlage gewünscht ist, kann in einem weiteren Verfahrensschritt 34 eine solche angestrebten Leistungserhöhung der Anlage definiert werden. In einem weiteren Verfahrensschritt 35 werden die für die angestrebte Leistungserhöhung notwendigen Regelreserven in den Regelkreisen der Anlage bestimmt und in einem weiteren Verfahrensschritt 36 die Regelkreise mit einer für die angestrebte Leistungserhöhung zu geringen Regelreserve ermittelt. Für die Regelkreise mit zu geringer Regelreserve können in einem weiteren Verfahrensschritt 37 technische und/oder technologische Untersuchungen der Regelkreise durchgeführt und Maßnahmen zur Herstellung der jeweilig benötigten Regelreserven durch Entlastung der jeweiligen Regelkreise und/oder durch Ersetzen von Komponenten in den jeweiligen Regelkreisen durch leistungsfähigere Komponenten erarbeitet werden. In einem weiteren Verfahrensschritt 38 kann für diese Maßnahmen eine technische und/oder betriebswirtschaftlichen Bewertung erfolgen, auf Basis derer eine abschließende Implementierung der Maßnahmen im Verfahrensschritt 39a erfolgt.If a further increase in output is desired in the system, such a desired increase in output of the system can be defined in a further method step 34. In a further method step 35, the control reserves required for the desired increase in power are determined in the control loops of the system, and in a further method step 36 the control loops are determined with a control reserve that is too low for the desired increase in power. For the control loops with too little control reserve, technical and / or technological investigations of the control loops can be carried out in a further method step 37 and measures can be developed to produce the respectively required control reserves by relieving the respective control loops and / or by replacing components in the respective control loops with more powerful components become. In a further method step 38, a technical and / or business assessment can be carried out for these measures, on the basis of which the measures in step 39a are finally implemented.
Die für die Leistungsfähigkeit einer Anlage relevanten Pro- zessgrößen können dadurch auf einfache Weise festgestellt werden, dass im übertragenen Sinne die an sich aus der technischen Mechanik bekannte Methode des "Freischneidens" angewandt wird.The process variables relevant to the performance of a system can be determined in a simple manner by applying the method of "free cutting", which is known per se from technical mechanics.
Hierzu wird in einem ersten Schritt eine die Leistungsfähigkeit der Anlage repräsentierende Prozessgröße ermittelt. Im Fall einer Anlage zur Papierherstellung handelt es sich z.B. um die Geschwindigkeit des Papiers in der Anlage.For this purpose, a process variable representing the performance of the plant is determined in a first step. In the case of a paper manufacturing plant, e.g. the speed of the paper in the system.
In einem nächsten Schritt wird, wie prinzipiell in FIG 3 dargestellt, ein Kernprozess 6 der Anlage definiert und sämtliche Schnittstellen 21 - 25 des Kernprozesses 6 zu den ihn umgebenden Nebenprozessen 41 - 45 (z.B. Nebenprozessen zur E- nergie-, Wasser- und Druckluftversorgung) bestimmt und auf Wirkungszusammenhänge mit dieser repräsentierenden Prozessgröße untersucht. Dies kann durch messtechnisches Erfassen der physikalischen Effekte (z.B. Kräfte, Ströme, Felder, Durchflüsse, Drücke) an diesen Schnittstellen erfolgen. Die Messung dieser physikalischen Effekte bzw. Prozessgrößen kann durch bereits vorhandene und/oder zusätzlich vorzusehendeIn a next step, as shown in principle in FIG. 3, a core process 6 of the system is defined and all interfaces 21-25 of the core process 6 to the secondary processes 41-45 surrounding it (for example secondary processes for the supply of energy, water and compressed air). determined and examined for correlations with this representative process variable. This can be done by measuring the physical effects (e.g. forces, currents, fields, flow rates, pressures) at these interfaces. The measurement of these physical effects or process variables can be provided by existing and / or additional ones
Signalgeber erfolgen, die gegebenenfalls an den Schnittstellen angebracht werden müssen. Findet sich an einer Schnittstelle ein WirkungsZusammenhang mit der repräsentierenden Prozessgröße, so liegt an dieser Schnittstelle eine für die Leistungsfähigkeit der Anlage re- levante Prozessgröße vor und es wird für die Komponenten des Nebenprozesses eine genauere messtechnische Untersuchung zur Bestimmung der Regelreserven durchgeführt. Die Schnittstellen ohne WirkungsZusammenhang werden nicht weiter betrachtet und statt dessen die Schnittstellen enger um den Kernprozess ge- zogen bzw. in das Innere des Kernprozesses verlegt und an diesen neuen Schnittstellen auf einen WirkungsZusammenhang mit der repräsentierenden Prozessgröße untersucht. Auch hierbei werden Schnittstellen mit WirkungsZusammenhang mit der repräsentierenden Prozessgröße als relevante Prozessgrößen identifiziert, für die in weiteren Schritten genauere messtechnische Untersuchung zur Bestimmung der Regelreserven durchgeführt werden.Signal transmitters take place, which may have to be attached to the interfaces. If there is an interdependency with the representative process variable at an interface, a process variable relevant to the performance of the system is available at this interface and a more precise metrological analysis is carried out for the components of the secondary process to determine the control reserves. The interfaces without an impact context are not considered any further and instead the interfaces are drawn closer to the core process or relocated to the inside of the core process and examined at these new interfaces for an impact context with the representative process variable. Here, too, interfaces with an effect connection with the representative process variable are identified as relevant process variables, for which more precise metrological investigations are carried out in further steps to determine the control reserves.
Durch ein solches systematisches, schrittweises "Engerziehen" der Schnittstellen von den Nebenprozessen bis hinein in den Kernprozess wird sichergestellt, dass nicht nur im Bereich des Kernprozesses sondern auch im Bereich der Nebenprozesse sämtliche für die Leistungsfähigkeit der Anlage relevanten Prozessgrößen ermittelt werden.Such a systematic, gradual "tightening" of the interfaces from the secondary processes to the core process ensures that not only in the area of the core process but also in the area of the secondary processes, all process variables relevant to the performance of the system are determined.
Im Fall einer Anlage zur Papierherstellung kann als Kernprozess z.B. der auf der Papiermaschine ablaufende Teilprozess definiert werden. Schnittstellen zu Nebenprozessen mit Wirkungszusammenhängen mit der Geschwindigkeit des durchlaufen- den Papiers finden sich dann v.a. im Bereich der Material- und Energieflüsse, so z.B. bei der Zufuhr von Energie, Dampf, Wasser, Fasern, Chemikalien und Zuschlagstoffe sowie der Abfuhr von Wasser, Kondensat und Abwärme. Die relevanten Prozessgrößen im Bereich der Nebenprozesse sind somit in diesem Fall - wie in FIG 4 dargestellt - die Energiezufuhr 51 (z.B. gemessen als Leistung P) , die Dampfzufuhr 52 (gemessen als Volumen pro Zeiteinheit) , die Wasserzufuhr 53 (gemessen als Volumen pro Zeiteinheit) , die Faserzufuhr 54 (gemessen als Masse pro Zeiteinheit) , die Chemikalienzufuhr 55 (gemessen als Masse pro Zeiteinheit) , die Wasserabfuhr 56 (gemessen als Volumen pro Zeiteinheit) , die Kondensatabfuhr 57 (gemessen als Volumen pro Zeiteinheit) und die Abwärmeabfuhr 58 (gemessen als Leistung P) . Diese relevanten Prozessgrößen können nun unter wechselnden Betriebsbedingungen der Anlage, z.B. für verschiedene Qualitäten und Sorten von Papier, erfasst und - wie nachstehend erläutert - die Regelreserven in den Regelkreisen der Anlage zur Papierherstellung ermittelt werden.In the case of a plant for paper production, the sub-process running on the paper machine can be defined as the core process. Interfaces to secondary processes with interdependencies with the speed of the paper passing through are then found primarily in the area of material and energy flows, for example in the supply of energy, steam, water, fibers, chemicals and additives as well as the removal of water, condensate and waste heat. In this case, the relevant process variables in the area of secondary processes are - as shown in FIG. 4 - the energy supply 51 (measured, for example, as power P), the steam supply 52 (measured as volume per unit of time), the water supply 53 (measured as Volume per unit time), the fiber supply 54 (measured as mass per unit time), the chemical supply 55 (measured as mass per unit time), the water discharge 56 (measured as volume per unit time), the condensate discharge 57 (measured as unit volume per unit time) and the Waste heat removal 58 (measured as power P). These relevant process variables can now be recorded under changing operating conditions of the plant, for example for different qualities and types of paper, and - as explained below - the control reserves in the control loops of the plant for paper production can be determined.
Mit Hilfe von FIG 5 und FIG 6 soll eine vorteilhafte Vorgehensweise zur Bestimmung der Regelreserve bei einem Elektro- motor zum Antrieb einer Papiermaschine der Anlage 1 gemäß FIG 1 erläutert werden. Die Vorgehensweise ist grundsätzlich auch auf die anderen Regelkreise der Anlage (z.B. Dampf, Vakuum, Beschichtung) anwendbar.An advantageous procedure for determining the control reserve in an electric motor for driving a paper machine of the system 1 according to FIG. 1 is to be explained with the aid of FIGS. 5 and 6. The procedure is basically also applicable to the other control loops of the system (e.g. steam, vacuum, coating).
Bei einer bestimmten Geschwindigkeit v des Papiers in der Papiermaschine liegt eine bestimmte Last (Drehmoment) M am E- lektromotor vor. Dieser Betriebspunkt definiert eine bestimmte Klasse K in der in FIG 4 dargestellten Geschwindig- keits/Last-Ebene v/M. Für jede Klasse K wird die Zeit (Ver- weildauer) T gezählt, in der der Motor in dieser Klasse betrieben wird und in einer Ebene senkrecht zur v/M-Ebene dargestellt. Es können somit die Klassen K mit den längsten Verweildauern ermittelt werden. Diese können anschließend angenähert durch einen lineare Zusammenhang zwischen Last M und Maschinengeschwindigkeit v beschrieben und durch eine Gerade G dargestellt werden. Grundsätzlich kann der Zusammenhang zwischen Last M und Maschinengeschwindigkeit v natürlich auch durch komplexere Funktionen beschrieben werden.At a certain speed v of the paper in the paper machine, there is a certain load (torque) M on the electric motor. This operating point defines a certain class K in the speed / load level v / M shown in FIG. For each class K, the time (dwell time) T is counted in which the engine is operated in this class and is shown in a plane perpendicular to the v / M plane. The classes K with the longest dwell times can thus be determined. These can then be described approximately by a linear relationship between load M and machine speed v and represented by a straight line G. In principle, the relationship between load M and machine speed v can of course also be described by more complex functions.
Das Diagramm der FIG 6 zeigt über der Geschwindigkeit v der Maschine das Drehmoment M des Motors, wobei diese beiden Parameter durch einen linearen Zusammenhang gemäß FIG 4, darge- stellt durch die Gerade G, angenähert sind. Bei einem drehzahlgeregelten Antrieb ist die maximale Leistung eines Motors oder Umrichters (je nachdem, welche geringer ist) ein hyperbolische Kurve HK in der Geschwindigkeits/Last-Ebene v/M. Der Abstand RV dieser hyperbolischen Kurve HK zu der Gerade G ist ein Maß für die Regelreserve und somit für die maximal mögliche Geschwindigkeitserhöhung.The diagram in FIG. 6 shows the torque M of the motor over the speed v of the machine, these two parameters being shown by a linear relationship in accordance with FIG. represents through the line G, are approximated. With a speed-controlled drive, the maximum power of a motor or converter (whichever is lower) is a hyperbolic curve HK in the speed / load level v / M. The distance RV of this hyperbolic curve HK to the straight line G is a measure of the control reserve and thus of the maximum possible speed increase.
Im Fall der Bestimmung der Regelreserve z.B. bezüglich der Positionierung eines Vakuum- oder Dampf- Steuerventils, Geschwindigkeit und Last eines Hilfsantriebs, von Flüssigkeitsströme etc. kann die Maschinengeschwindigkeit statt über der Last auch über der Position des Ventils, der Geschwindigkeit des Hilfsantriebs oder dem Flüssigkeitsstrom aufgetragen, die Verweildauer bestimmt und der angenähert lineare oder komplexere Zusammenhang mit der Geschwindigkeit v bestimmt werden.If the control reserve is determined, e.g. With regard to the positioning of a vacuum or steam control valve, speed and load of an auxiliary drive, of liquid flows etc., the machine speed can also be plotted instead of over the load over the position of the valve, the speed of the auxiliary drive or the liquid flow, the residence time determined and approximated linear or more complex relationship with the velocity v can be determined.
Die im Fall einer Anlage mit einem kontinuierlichen Produkti- onsprozess, z.B. einer Anlage zur Papierherstellung, zu be- trachtenden Prozesse sind in der Regel nicht sehr dynamisch. Die dynamischen Anteile in den Prozessgrößen sind sogar für die Bestimmung der Regelreserven nicht in erster Linie interessant. Von größerem Interesse ist vielmehr das durchschnittlichen Langzeitverhalten der Prozessgrößen. Die Pro- zessgrößen werden deshalb bevorzugt gefiltert (ca. 2 s) und nur ca. alle 5s abgetastet.In the case of a plant with a continuous production process, e.g. A system for paper production, processes to be considered are usually not very dynamic. The dynamic components in the process variables are not of primary interest even for the determination of the control reserves. Rather, the average long-term behavior of the process variables is of greater interest. The process variables are therefore preferably filtered (approx. 2 s) and only sampled approx. Every 5s.
Bevorzugt wird eine Online-Auswertung der erfassten Daten mit anschließender Datenkompression für eine nachfolgende Off- line-Auswertung der erfassten Daten durchgeführt. An online evaluation of the recorded data with subsequent data compression is preferably carried out for a subsequent offline evaluation of the recorded data.
Claims
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| DE10326428 | 2003-06-10 | ||
| PCT/EP2004/006258 WO2004109571A1 (en) | 2003-06-10 | 2004-06-09 | Method for increasing the capacity of an installation used to carry out an industrial process |
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| EP04736391A Withdrawn EP1631936A1 (en) | 2003-06-10 | 2004-06-09 | Method for increasing the capacity of an installation used to carry out an industrial process |
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| CN109507468A (en) * | 2018-12-21 | 2019-03-22 | 九州能源有限公司 | A kind of header box branch current detection method and system based on linked character |
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| US8590325B2 (en) | 2006-07-19 | 2013-11-26 | Emerson Climate Technologies, Inc. | Protection and diagnostic module for a refrigeration system |
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| DK2012404T3 (en) * | 2007-07-03 | 2013-12-02 | Silver Stone Technology Co Ltd | Selective, independent overload and group overload protection circuitry for power supply |
| US20090037142A1 (en) | 2007-07-30 | 2009-02-05 | Lawrence Kates | Portable method and apparatus for monitoring refrigerant-cycle systems |
| US8393169B2 (en) | 2007-09-19 | 2013-03-12 | Emerson Climate Technologies, Inc. | Refrigeration monitoring system and method |
| US9140728B2 (en) | 2007-11-02 | 2015-09-22 | Emerson Climate Technologies, Inc. | Compressor sensor module |
| EP2149954B1 (en) * | 2008-07-31 | 2018-09-05 | ABB Schweiz AG | An interface module for communication with an electronic or an electro-mechanical device of a medium voltage interruption unit. |
| DE102008039450A1 (en) * | 2008-08-25 | 2010-03-04 | Kernkraftwerke Lippe-Ems Gmbh | Method for detecting operating condition of electrical appliance i.e. electrical heating device, and for disconnecting appliance in non-determined operating condition, involves disconnecting electrical appliance from supply voltage |
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| DE102012023459B3 (en) * | 2012-11-30 | 2014-05-15 | Volkswagen Aktiengesellschaft | Electrical system for e.g. truck, has second current measuring unit that carries out current measurement in specific component path at which electrical component of specific-type is arranged, during operation of respective component |
| US9803902B2 (en) | 2013-03-15 | 2017-10-31 | Emerson Climate Technologies, Inc. | System for refrigerant charge verification using two condenser coil temperatures |
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- 2004-06-09 WO PCT/EP2004/006258 patent/WO2004109571A1/en not_active Ceased
- 2004-06-09 CA CA2528778A patent/CA2528778C/en not_active Expired - Fee Related
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| CN109507468A (en) * | 2018-12-21 | 2019-03-22 | 九州能源有限公司 | A kind of header box branch current detection method and system based on linked character |
Also Published As
| Publication number | Publication date |
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| EP1487077A3 (en) | 2005-04-20 |
| CA2528778A1 (en) | 2004-12-16 |
| EP1487077A2 (en) | 2004-12-15 |
| WO2004109571A1 (en) | 2004-12-16 |
| CA2528778C (en) | 2014-04-01 |
| BRPI0411315A (en) | 2006-07-18 |
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