Some enterprises in their economic jurisdiction have transformer substations (TP). They are consulted by the Hephaestus company. Such companies incur large losses due to reactive as well as active losses of TP. Measurements, laboratory tests, and their maintenance also require investments. The owners of the companies do not see any visible profit and consider these investments as costs. This is due to the fact that there is a constant expenditure of money, but nothing is produced. However, the presence of its own TP means high-quality electricity, as well as the uninterrupted generation of it. To make a profit, it is necessary to calculate the balance of economic and production costs. This is possible through the design of the TP.

Flaws in the design of TP
The design of the TP, as well as the design of the electrics, is carried out according to the developed schemes. When designing a TP, a technical task is developed for the designer, then a diagram of the TP and switchgear is developed, the required power of the transformer, protection, grounding, short-circuit currents is calculated. After calculations, the necessary equipment is selected (insulators, transformers, buses, etc.). Then the draft law of the TP is coordinated with the authorized bodies. The final stage is the transfer of the project to the customer, after which the electrical installation begins. We must not forget about the analysis of the work done: testing, conclusion of contracts, the beginning of use.

Consider an example of designing a TP in Moscow
The Gefest company was entrusted with the project for the design of the TP at the bakery. The enterprise was already in operation, it was required to reconstruct the TP built there in order to reduce the cost of its maintenance and increase its efficiency. The bakery has two oil-immersed transformers, one of which is reserve, and the second is used only by 60%. The enterprise works to a maximum of only 8 hours a day due to the technological features of production: bread is baked for 8 hours, the rest of the time is spent on preparation (dough is prepared, dough is kneaded). The plant also produces pasta (the equipment in this workshop consumes quite little energy).

The Gefest company has calculated the energy consumption of the bakery. It was revealed that the enterprise was paying the supplier for the electricity of both transformers, as well as reactive consumption. TPs were not equipped with metering devices, so all calculations were carried out according to established standards, naturally, in favor of the supplier. Although the transformers were not used to their full capacity, the plant paid in full for the entire cost of use. In the course of the design solution to the problem, the TM-600 was replaced with a TM-400 of lower power, the RU-10 circuit was reconstructed, namely, the spare transformer was turned off, but if necessary, it could be turned on instantly. TM was equipped with a condensing unit that operates automatically, which reduced generation and flow costs.

it took a month to develop, approval went on for a week, and it took two weeks for reconstruction and laboratory tests. This is a rather costly process. Initially, Hephaestus calculated the economic efficiency and payback period (28 months). It follows from this that the design of the TP is an important stage that helps to save money.

It is also necessary to assess the possibility of providing backup power, the correspondence of the power of transformers and the load on them, the need to install compensating devices, modes of consumption, the need to install metering devices.In order to properly design power supply systems, it is important not only to know the regulatory and technical documentation and have technical skills.

The design of APCS systems of any degree of complexity is necessary for creation of a ready-made infrastructure for an automated process control system in production... The specialists of "Neftegazengineering" LLC design the process control systems for both newly constructed facilities and already operated enterprises. In the latter case, the goal of creating a new automated system is to change the technological process, increase the productivity of processes, improve the quality of products or services provided, reduce operating costs and other benefits as a result of the most optimal control of technological processes.

Effective administration of technological processes includes not only management functions, but also information properties, measuring the parameters of the system's operation, collecting, storing and analyzing information and then forming an algorithm for the system's operation.

In order for the entire automated control system to work efficiently, smoothly and reliably and was maximally adapted to the requirements at the facility, it is necessary to design the automation system for the automated process control system to create the most optimal and rational level of automation of the technological process.

Process control system design stages

The main stages of work on the design of APCS systems are:

  • pre-design stage
  • development of a draft design
  • development of a technical project
  • development of working documentation (for installation work)
  • coordination of the project with the Customer
  • obtaining a state expert opinion

On pre-project preparation a technical audit, examination and analysis of the specifics of the object are carried out, as a result of which preliminary design solutions are developed. If the Customer already has a technical assignment, our specialists draw up an estimate for the design of an automated process control system. Based on the results of the budget approval and upon concluding a service contract, the design engineers of the automated process control system begin to develop the project of the automated process control system.

V APCS project(in the technical and working documentation) the concept of the system is being developed, which allows the most successful implementation of the entire project of the automated process control system as a whole. The project provides basic information about the developed automated control system for technological processes. For example, the project contains a set of technical means of automation (instrumentation, software, etc.), their hierarchy, drawings and structural and functional diagram of the optimal placement. Design engineers of OOO NGI are working on a ready-made working scheme for automation and dispatching of production processes at the facility.

All design stages are carried out in accordance with state regulations, namely:

  • GOST 34.601-90 "Automated systems. Stages of creation"
  • GOST 34.201-89 "Types, completeness and designation of documents when creating automated systems"
  • Government Decree No. 87 of "On the composition of sections of project documentation and requirements for their content"

During the construction or reconstruction of transformer substations, it is impossible to do without performing certain works. For example, it is a complex measure, which in these cases is subject to mandatory implementation.

Substation design in the context of constantly growing volumes of energy consumption, it should be based on certain aspects that are directly related to the peculiarities of the operation of the installed equipment. These include climatic and technical conditions of TP operation, power consumption and equipment load, as well as some additional parameters.

The performance of work related to calculations and design must necessarily be based on a number of regulatory documents:

  • rules governing the operation of electrical installations (PTEEP);
  • set of rules for PUE;
  • rules governing the operation of power grids and substations;
  • rules for the safe operation of high-voltage equipment;
  • fire safety requirements;
  • operational safety requirements for machinery and equipment.

Urban TP design

The calculation and design process can be considered using the example of a city substation.

First of all, the designers must determine the power of the transformer installation. It is calculated based on the expected load of the equipment. This takes into account the operating conditions and the likelihood of overloads in the operation of the substation.

Formally transformer substation design is carried out in several stages:

  • preparation of technical specifications;
  • monitoring the operation of the existing substation (if any) and analysis of its main indicators;
  • development of project documentation;
  • preparation of technological documentation;
  • approval of the finished project;
  • consideration of the project by members of the expert commission and drawing up executive documentation;
  • delivery of the agreed documentation to the customer or his representative.

Designers should take into account that transformer substation, buy which can be either from the manufacturer or through an intermediary organization (engaged in the design and installation of such equipment), must meet the requirements and wishes of the customer. In this case, all design calculations must be brought in accordance with the standards and operating conditions of the installation. Effective substation design takes into account the design features of the equipment, the timing of the project and the budget allocated for it.

The documentary part of the project consists of several sections:

  • from the explanatory note;
  • construction estimates;
  • master plan of the facility being created, which indicates the installation locations of the transformer equipment and the layout of the technical premises;
  • from the elaborated and approved technological sequence of construction works;
  • from a schematic plan for the location of utilities and equipment.

Also, the general package of documents includes a list of measures for labor protection and civil defense.

Installation of transformer substations is carried out on the basis of a carefully worked out, agreed and approved project, which is the guarantor of compliance with the current rules and regulations. Such a project should be developed by a specialized organization with the participation of experienced and qualified specialists.

The transition to the use of advanced technology is an innovative stage in the development of Russian industrial production, which seeks to achieve extremely high performance in both used and new designed equipment. This is done in order to minimize any loss in production figures. The use of automated control systems for technological processes (APCS) is the only condition for the existence of high quality management and control of industrial facilities.

APCS is a single system solution that will provide you with the automation of the main tasks and processes in production and its individual sections. The very concept of "automated" explains the need for the participation of the human factor in individual operations to further maintain control over the process.

Designing an automated process control system is a focused process of increasing the productivity of all industrial enterprises, the quality of manufactured products and safety at the facility. Also, the automated process control system additionally provides the latest quality in the administration of production processes. This is always true for any modern enterprise. The need for an automated process control system appears when technological processes are characterized by increased complexity and the inadmissibility of failures that will lead to significant material losses. Exceptionally competent design of the automated process control system significantly reduces the likelihood of outside influence of the human factor on the entire operation of the enterprise. One of the main and mandatory functions is archiving. After all, it is very important to be able to analyze the operation of systems for global analysis in slow, long-term processes.

The structure of the APCS, which works as a unified operator control system, includes:

  1. one or more control panels;
  2. special means of collecting, transporting, processing and archiving information about the course of the production process;
  3. typical equipment: controllers, sensors and other automation equipment;
  4. industrial networks used for information communication of subsystems;

The diagnostic system of the automated process control system monitors the state of all components in production, thereby increasing the quality and service life of mechanisms and machines. In turn, the development and implementation of APCS systems are interrelated processes, including the design of APCS, software, dispatching, as well as programming of controllers.

Highly qualified specialists of FLEX CONTROLS LLC provide you with a full integrated design of the process control system, developing a unique package of design and technical documentation for all automated control systems, as well as systems for collecting and transporting various information for the needs of any industry. At the same time, our specialists carry out individual supervision at the stages of installation of an object and at its commissioning.

Our Company offers you qualified and effective solutions that will definitely bring concrete practical results that increase the productivity ratio. The leading specialists of our company have extensive experience in the creation and implementation of automated process control systems at various enterprises of the chemical and petrochemical industries.

10.04.2017 15:12:10

For ELATRO, the design of automated process control systems in Moscow is one of the core areas of work. This process involves the implementation of a fairly large amount of preparatory work, the direct development of the system, its commissioning with a complex of tests. The stages of the development of the APCS are maintained quite clearly, regardless of the characteristics of the technological process and the direction of the enterprise.

How is the design carried out

  • Formation of technical specifications

The work begins with the formation of a list of requirements for the future ACS based on a survey of the facility, a list of customer requirements, and the results of an audit in certain areas. If necessary, a complex of studies can be carried out aimed at a more detailed study of the object. As a result, reporting documentation is formed, on the basis of which the design concept and the technical task itself are developed.

  • Design

The design of automated process control systems in Moscow with the development of appropriate documentation by our company is carried out in several stages:

  1. preliminary (sketch) design solutions;
  2. development of documentation for ACS and its individual parts;
  3. formation of technical specifications for the development of equipment for assembly, preparation of documentation for the supply of finished equipment;
  4. creation of a package of working documentation;
  5. software development or its adaptation to a specific system.