Acrel Intelligent Control & Wireless Temperature Monitoring Application in Lee & Man Paper’s Sepang Power Station, Malaysia

Abstract:

To prevent fires caused by high temperatures arising from loose wire joints, cable aging and other issues, which may lead to enormous economic losses, it is essential to implement safe temperature monitoring and intelligent control for electrical equipment. Typical monitoring locations include high-current cable joints, locally overheating sections of power equipment, moving and static contacts in switchgear, incoming and outgoing busbar joints, electrical contacts in rectifier cabinets, transformer connection points, and critical electrical joints in substations or outdoor power circuits. Our company’s Intelligent Control Series products can effectively address such problems.
Keywords: High-voltage Switchgear; Intelligent Control Device; Wireless Temperature Measurement

Overview

Substation operating equipment such as busbars, cables and circuit breakers operates continuously under high-voltage and heavy-current conditions. Temperature monitoring and maintenance of such equipment constitute an indispensable part to ensure reliable power grid operation. Especially for enclosed equipment including high-voltage switchgear and gas-insulated switchgear (GIS), heat dissipation is inherently poor. Routine manual temperature measurement cannot achieve direct and online temperature monitoring of components inside cabinets. Owing to the lack of effective online temperature monitoring and early-warning systems, fires caused by overheated substation equipment have been frequently reported in recent years. Such incidents severely impair power supply reliability, bring substantial economic losses to power utilities, and may even result in personal injury or fatalities.

Lee & Man Paper has invested in four 5600/900 packaging paper machine production lines (PM23, PM25, PM26 and PM27) at its Sepang paper manufacturing base in Malaysia, with an average daily pulp output of 1,000 tonnes. The captive power plant supporting the production lines is under steady construction. The gas turbine installation works for Phase II captive thermal power plant involve two sets of 30 MW gas turbines and associated auxiliary facilities.

A stable and reliable power system serves as a vital foundation for enterprise development. Therefore, adopting rational, effective and dependable temperature measurement technology to conduct real-time online monitoring of heat-prone locations such as current transformers, busbars, cables and switch contacts is of great significance. It enables timely detection and alarm of abnormal temperature risks so as to guarantee reliable operation of substation equipment.

Product Requirements and Configuration

The project implements safety temperature monitoring, measurement and control for 67 high-voltage cabinets in the thermal power station, including incoming cabinets, PT cabinets and outgoing cabinets. Wireless temperature monitoring and intelligent control products are required. Detailed specifications are listed below:

1. Dynamic mimic diagram, high-voltage live display and interlock control;
2. Energy storage indication, live voltage and anti-misoperation voice prompt;
3. Two-channel automatic temperature & humidity control and display; communication cable length: 6 m;
4. Remote/local control and switch closing/opening operation;
5. Cabinet lighting control;
6. RS485 / Modbus communication interface;
7. Human body induction function;
8. Pre-close / pre-open flashing indication;
9. Temperature measurement and display for electrical contacts; 6 temperature measuring points per high-voltage cabinet;
10. Wireless transmission with energy harvesting power supply; starting current ≥5 A; measuring range: -50℃ ~ 125℃; integrated sensor and power supply module; service life ≥10 years; measurement accuracy: ±1℃;
11. Real-time monitoring: temperature sensors transmit real-time temperature data to receivers. Receivers forward data to intelligent control units (upload frequency configurable), which further transmit data to the background system to guarantee real-time data acquisition.
In accordance with the above requirements, Acrel wireless temperature monitoring products are selected as shown in the table below.

Conclusion

ASD320 and ASD100G intelligent control devices are new multi-functional intelligent mimic indication units specially designed for power switchgear. They integrate multiple functions including primary circuit mimic diagram, switch status, circuit breaker position, earthing switch position, spring energy storage status, disconnector status, voice anti-misoperation prompt, high-voltage live indication, wireless temperature measurement, high-voltage live interlock, automatic heating & dehumidification control, temperature and humidity regulation, heater fault indication and over-temperature alarm. These functions support safe and reliable electrical operation.