Modernization and development of electric drives and CNC control systems for metal-cutting and other machine tools (with the involvement of LLC RPE ENERGO-PLUS specialists)

Years of implementation

 

2013–2018
Project title

Modernization and development of electric drives and CNC control systems for metal-cutting and other machine tools (with the involvement of LLC RPE ENERGO-PLUS specialists):

  • Adjustable thyristor electric drive for an oil churning unit (Ukrainian-Bulgarian enterprise NAK, Podorozhne village)
  • Control system for a rings production machine for sleeve filters (Bag Filter Plant, Kremenchuk) 
  • Control system for interconnected electrical drives of a winding machine for the fiberglass pipes production (UkrIzolit, Svitlovodsk)
  • Modernization of electrical equipment of horizontal boring machine 2A535 (PJSC "KREDMASH")
  • Modernization of electrical equipment of the lathe 16K20T1 (UkrIzolit, Svitlovodsk) 
  • Modernization of electrical equipment of horizontal boring machine 2D450 (PJSC "Kremenchuk Steel Works") 
  • Repair and commissioning of the main movement electric drive type BTU 3501-R of the heavy lathe 1A660 (PJSC Kremenchuk Career Management "Kvarz")
  • Manufacturing, installation and commissioning of the electronic control system for the universal welding rotator M11050A (OBOD CJSC)
  • Development and manufacture of an electromechanical control system for the state of in-line winding of welding wire on cassettes (SE "ITSTS "SVITKERMET")
  • Modernization of the feed electric drive of the horizontal boring machine type 2A614-1 (PJSC "KREDMASH")
Type of worksDesign, supply of equipment, installation, commissioning
Equipment used; specifics of works provided

Modernization of processing machines using the following equipment and software: SI8 pulse counters, Lenze 8200 Vector frequency converter, PLC Vipa 100, operator panel OP7, Lenze 473 DC converter, Santerno DCREG2 DC drive (Italy), ETI relay and contactor equipment, ETU-3601 DC drive, NC-201M Balt-System CNC, ELL DC drive (Bulgaria), LIR-581 SPPU, Toshiba VFPS1, VF-S15 DC drives, Autonics encoders, Precizika Metrology linear converters, Autonics digital tachometer, FC OVEN, DC electronics BTU 3501-R, INVT GD100 frequency converters, Kinco PLC, Servo drives Lexium 32 (Schneider Electric), SoMove software

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Automation of the combustion safety system at the Centralized Processing Plant furnace unit No. 5 of the grinding body of the batch preparation section (automated process control system, combustion safety system), Mill path No. 5 (Ferrexpo Poltava Mining)

Year of implementation

 

2015
Type of works

Installation works, software development for PLC Mitsubishi Electric Melsec System Q, HMI and SCADA commissioning work

Equipment used; specifics of works provided

Installation of compressed air flow, pressure, and vacuum sensors manufactured by Yokogawa, Jumo, pneumatic control valves manufactured by InterApp, throttles manufactured by Beck, normally closed gas supply shut-off valves, ASCO purge valves, Maxon gas shut-off valve, igniters manufactured by Forney, igniter and burner flame control devices manufactured by Fireye, Raytek temperature measurement pyrometer in the furnace unit, Rosemount radar level gauges. Use of SCADA Citect and high-performance Mitsubishi MELSEC-Q series PLCs.

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Technical re-equipment of the raw water supply scheme for the ultrafiltration unit (UFU) at the TPP-5 chemical shop (Joint Venture “Kyivski TEC”)

Years of implementation

 

2016–2017
Type of works

Design, equipment supply, installation, software development, commissioning

Equipment used; specifics of works provided

A cascade control system to control four 37 kW pumping units with a uniform operating time, as well as a raw water tanks level control system were implemented. The layout and assembly of the control cabinets was carried out by the company's specialists using Siemens and Schneider Electric equipment. The system was programmatically integrated into the existing water treatment SCADA (SCADA SIMATIC WinCC).

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Adjustable micropower drive for coal hoisting machine MPB 5x2x2 ("Stepova" mine, Pershotravensk)

Year of implementation

 

2017
Type of works

Design, installation, equipment supply, software development, commissioning

Equipment used; specifics of works provided

The motion control system for the auxiliary electric drive of the coal hoisting machine in the functions of path, speed and acceleration by means of the DELTA FC embedded PLC was implemented

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Emergencies early detection and people notification, in case of emergencies occurrence, system at TPP LLC “Kremenchuk TEC” (branch of JSC "POLTAVAOBLENERGO")

Year of implementation

 

2017
Type of works

Upper level software development, commissioning works

Equipment used; specifics of works provided

The system is implemented using SCADA ZenOn 7.6, PLC Vipa 200

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Reconstruction and automation of section No. 12, DSP (density meters) (Ferrexpo Poltava Mining)

Year of implementation

 

2017
Type of works

Equipment supply, installation, commissioning

Equipment used; specifics of works provided

Supply works, installation and commissioning of equipment for continuous monitoring and measurement of a pulp density

Oxygen and natural gas metering at the BRM based on Ergomera equipment (Ferrexpo Poltava Mining)

Year of implementation

 

2017

Type of works

Installation and commissioning

Equipment used; specifics of works provided

Installation of measuring devices on the oxygen and natural gas supply pipelines at the Ferrexpo Poltava Mining BRM shop with the installation and adjustment of the accounting system, integration into company’s united network instrumentation system

Modernization of the sewage pumping stations SPS-4 and SPS-7 (Ferrexpo Poltava Mining)

Years of implementation2017–2018
Type of works

Construction, installation and commissioning works

Equipment used; specifics of works provided

The system is implemented using SCADA SIMATIC WinCC, Mitsubishi FC, Mitsubishi PLC

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Reconstruction of the 16 ATA steam supply scheme (LLC “Kremenchuk TEC”)

Years of implementation

 

2018–2020
Type of works

Design, installation, equipment supply, software development, comprehensive testing and commissioning

Equipment used; specifics of works provided

An automated control system to control valves of the steam supply system based on Modicon M241 Schneider Electric PLC with strict requirements for stabilizing the pressure at the consumer side was implemented

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Modernization of the automatic water level in boiler drums No. 1-4 regulation and control system (LLC “Kremenchuk TEC”)

Years of implementation

 

2018-2020
Type of works

Design, installation, equipment supply, software development, comprehensive testing and commissioning

Equipment used; specifics of works provided

Our company was the first in Ukraine to use Schneider Electric's flagship Modicon M580 controllers with hot redundancy. Installation of the LDM feed water control valve DN 225 RV701, with the medium parameters: T=230⁰ C, P=230 kgf/cm2 on welded joints with a wall thickness of 24 mm; installation of a feedwater and superheated steam flow sensor; the layout and assembly of the control cabinet was carried out by the company's specialists using Schneider Electric equipment; installation of an HMI and a manual control unit. An adaptive PID control algorithm with self-tuning coefficients was implemented. Automatic control in the static mode is carried out with a deviation of the water level in the boiler drum of no more than ±5 mm, control in the dynamic mode is up to ±30 mm of the water level in the boiler drum. A semi-automatic mode of switching from thread A to thread B and vice versa has been implemented.  A detailed analysis of the operation of the water level control system in the boiler drum was carried out using the obtained trends of the main system parameters

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Implementation of the Coastal Pumping Station (CPS) NDV adjustable electric drive system at TPP-6 (Joint Venture “Kyivski TEC”, TEC-6)

Year of implementation2019
Type of works

Adjustment of design and estimate documentation, installation works, software development, equipment supply, commissioning

Equipment used; specifics of works provided

An automated control system for pumping units based on Modicon M241 PLC and ATV630 Schneider Electric FC was implemented, taking into account various operating options for the modernized and existing equipment. During the commissioning, digital models of the control object were used for preliminary calculation of the regulators' parameters

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Technical re-equipment of the automatic control system (ACS) for the superheated steam temperature control of boilers TGM-84 st. No. 1, No. 2, No. 3, No. 4 (LLC “Kremenchuk TEC”)

Years of implementation2019–2020
Type of works

Design, installation, equipment supply, software development, comprehensive testing and commissioning

Equipment used; specifics of works provided

PID temperature control of superheated steam using rigid and flexible feedback is implemented on the basis of Schneider Electric Modicon M580 controllers with hot backup. 

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Adjustment of project documentation "DZF. Automatic pump control system 8NDV" (Ferrexpo Poltava Mining)

Year of implementation2021
Type of works

Project works

Equipment used; specifics of works provided

Adjustment of the control system project documentation for switching from PLC System Q (Mitsubishi Electric) to PLC Siemens 400H series

Automation of drying at 1, 3, 4 process lines at Centralized processing plant (Ferrexpo Poltava Mining)

Year of implementation2021
Type of works

Installation and commissioning

Equipment used; specifics of works provided

The project was carried out according to the repair schedules of the 1st, 3rd, 4th process lines. We carried out work on the modernization of the existing process control system of the lines, which included the replacement of controls and sensors (information and security), control cable lines, organization of intra-shop and inter-shop fiber-optic communication lines on the principle of a double ring, and commissioning. The system combined the production line process controls based on microprocessor control and SCADA process automation software

Monitoring of the current load of the mill ball drive electric drives at mill No. 21115, inv. No. 122992500 – 1st technological line, downstream – 3rd technological line. Combustion area No. 1 and No. 2 (Ferrexpo Poltava Mining)

Year of implementation2022
Type of works

Design work

Equipment used; specifics of works provided

Designing a current load monitoring system for electric drives based on TeSys T (Schneider Electric)

Modernization of the DZF unified control room of the (Ferrexpo Poltava Mining)

Year of implementation2021
Type of works

Installation, commissioning, project adjustment

Equipment used; specifics of works provided

Works on the implementation of the project of the ACS for technological processes SMD2 and SMS2, transfer of operational control to the Single Control Room (SCR), improvement of the SCR power supply system by introducing a UPS with ATS from 2 independent power sources. The inter-shop and intra-shop information circuit was made using the double independent ring technology, information signals were collected by the existing control panels and transmitted via control circuits to the installed microprocessor control cabinets. An uninterruptible power supply system from independent sources was implemented, which required redesign and construction of a cable route for laying a cable with a cross-section of 4x120 and a length of 780 meters. Lower-level commissioning works were carried out to search, check and input signals into the ACS system and the SCADA process automation software

Installation and commissioning of a set of equipment for water purification by reverse osmosis technology with a capacity of at least 16.6 m³/hour at the facility "New construction of a complex of buildings and structures for storage and processing of grain", ENSELCO-AGRO LLC

Years of implementation2020-2021
Type of worksPLC and HMI software development
Equipment used; specifics of works providedPLC Siemens S7-1500, HMI
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Construction of a water treatment plant at PJSC "POEZ-KERNEL GROUP" for the project implementation: "Reconstruction of the plant's steam supply system with the installation of a cogeneration unit with an electric capacity of 10.4 MW at PJSC "POEZ-KERNEL GROUP", address: 17 Marshala Biryuzova St., Poltava

Years of implementation2021-2022
Type of works

Installation, commissioning, project adjustment

Equipment used; specifics of works provided

Implementation of the automatic control system for the water treatment plant, including measuring and control equipment based on modern hardware and software without the presence of personnel. Development and implementation of the software complex "automated workstation of the water treatment plant operator (SCADA)", with equipment monitoring and control in the control room of the thermal power plant and the water treatment plant machine room

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Design and commisioning of the control and safety system for the GM-3 hydraulic unit at the Tashlyk Hydro-Atomic Power Plant (HAPP)

Year of implementation2022
Type of works

Design, comprehensive commissioning and testing

Equipment used; specifics of works provided

OVATION software and hardware complex, ELEKTROTECHNIKA transformer and excitation system, and SIEMENS duplicate synchronizers. The design and commissioning took into account the specifics of different equipment manufacturers, and ensured the docking and interface of these systems. Tests were conducted at different power levels, both in generator and pumping modes

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Setting-up an automatic frequency control station for electric motors of network pumps with the installation of an automatic reserve input cabinet at boiler houses at 193-a Mira Avenue and 151-a Mira Avenue, Chernihiv

Year of implementation2022
Type of worksInstallation and commissioning
Equipment used; specifics of works provided

The control cabinet contains a KINCO-K532 programmable logic controller (PLC) kit and a KINCO GL100E touch panel (10.1" 16770K color TFT 1024*600 high resolution) for displaying operating modes and viewing the event log. The frequency converter cabinets are based on Control Techniques NE300 series frequency converters: NE300-4T0550G/0750P (55/75 kW 380B-440B) or NE300-4T0750G/0900P (75/90 kW 380B-440B). To ensure electromagnetic compatibility with the grid and reduce current consumption fluctuations, Lenze three-phase EZAELN 75kW or 90kW line chokes are used at the FC input. The FC input circuits are protected by an NSX160N 150A circuit breaker (CB) with a MICROLOGIC 2.2M high-speed electronic disconnector. Bypass circuits are provided in the FC to enable direct start of the induction motors (IM) of the IA. The motor protection is carried out using EASYPACT EZC250N 3P3T 25kA 160A and thermal relay. A multifunctional 3-phase power control relay is used to control the order of supply voltage phases alternation  

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Technical re-equipment of the wastewater treatment unit by applying the complex technology of membrane water treatment by reverse osmosis (PJSC “UKRTATNAFTA”)

Year of implementation2022
Type of works

Development of project documentation, installation, commissioning, development of a dispatching and control system using WinCC Runtime Advanced V17 software

Equipment used; specifics of works provided

The object of automation is the technological process of removing salts from the water recycling system of the enterprise by membrane water purification using reverse osmosis. The product of the complex is desalinated water of a given quality.

The total capacity of the complex is 120 m3/h, with two lines of 60 m3/h each, with the possibility of a complete shutdown of one of the lines, including all the necessary stages of preliminary treatment of wastewater before it is fed to the membrane treatment unit, buffer tanks and provides for the possibility of operation at low ambient temperatures. The technology uses chemicals supplied to the system through dosing stations.

The chemical composition of the water is monitored by appropriate control devices at different parts of the system.

The automated control system of the integrated technology of membrane water purification by reverse osmosis is implemented using Siemens S7-300 series control equipment and ET200M distributed peripherals.

Visual control over the process operation and its regulation is carried out from the operator's automated workstation (AWS) with SCADA or touch panel.

The pumps are equipped with automatic frequency control using Schneider Electric frequency converters

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Setting up control systems and a dispatching system for autonomous boiler houses (11 units) in Chernihiv (JSC "OBLTEPLOCOMUNENERGO")

Year of implementation2022
Type of works

Installation, development of customized boiler room software and SCADA system, commissioning and comprehensive testing

Equipment used; specifics of works provided

Additional equipment of boiler houses to automate the start-up and operation process, adaptation of existing equipment to automation requirements

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Technical re-equipment of the automated control system for pumping units (ACS PU) (Municipal Enterprise "Lubny-Vodokanal")

Year of implementation2022
Type of works

Dismantling, installation, equipment supply, software development, comprehensive testing and commissioning

Equipment used; specifics of works provided

Replacement and adjustment of morally and physically outdated equipment with pumping units (110 kW). Schneider Electric equipment was used: cabinet-type FC ATV950C11N4F, TM200 PLC, HMIET6400, switching equipment. The commissioning works were carried out to ensure a smooth pressure build-up according to the set point, stable pressure maintenance, and automatic switching between pressure set points depending on the time of day

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TPP reconstruction at Ltd. “Euro-Rekonstruktsia” (Darnytsia TEC) with the conversion of boiler units No. 6, No. 7, No. 8 to burn non-designed fuel (gas group coal)

Year of implementation2022
Type of worksManufacturing, installation and commissioning
Equipment used; specifics of works provided

According to the project, the following works were implemented:

  • laying of cold air pipelines from DV at the mills imputs, equipping the hot and cold air pipelines with regulating dampers to ensure that the temperature behind the mill is maintained at about 70°C in a wide range of fuel quality and load limits;
  • supplying the distribution ramp of the transport air with a pipeline of low-heated air taken after the first stage of the air heater with a control gate to ensure that dust is supplied to the burners both during operation and during MB shutdown, and the temperature of the air mixture in front of the burners is no higher than 170°C, and no higher than 150°C in the case of a filled dust duct;
  • replacement of dust ducts from dust feeders to burners with a smaller diameter to ensure the air mixture velocity if the dust ducts exceeds 25 m/s.

To monitor the normal operating mode violation features, the dust system is equipped with control points for technological parameters:

  • Exceeding the maximum permissible temperature at any point of the dust system;
  • Exceeding the permissible temperature at the burner inlet (for example, due to malfunctioning of dust feeders, smoldering in mixers, clogged dust ducts, etc;)
  • Overloading of the mill; 
  • Increase the pressure in the dust system to the designed pressure value of operation of explosive safety valves
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