Frequency voltage drives and soft starters

Frequency voltage drives (VFD) or soft starters (SS) are used for automation of installations with electric motors, motor speed control, energy-saving, and help to reduce operating costs and deterioration of operating mechanisms.

Soft starters make it possible to have а smooth (reduced-current) start and deceleration of electric motors.

The greatest economic effect is achieved due to use of frequency converters for pumps and fans in case of relatively large extent of motor speed control. Use of frequency converters in the systems of ventilation, conditioning and water supply have actually become a standard.

Today, the market offers a variety of modifications of frequency converters and soft starters of various manufacturers. BPA relies on high quality drives produced by the world-wide leaders of this direction:

- Rockwell Automation (Allen-Bradley),

- ABB,

- Siemens,

- Danfoss,

- Schneider-Electric.

    

Supply of converters made by other manufacturers is possible at the Customer’s request.

BPA offers full range of services for implementation of frequency converters and soft starters for voltage rating from 0.4kV to 10kV:

- integrated survey inspection of electrical installations,

- development and justification of technical solutions,

- development of requirement specifications,

- designing,

- expert examinations of projects,

- justification of projects and electrical installation in the supervision bodies

- manufacture of certified cabinets with frequency converters and soft starters (low-voltage package modules of MCC type),

- delivery of electrical equipment to any destination point within the country and abroad,

- construction and installation works, erection supervision, commissioning and start-up works,

- advisory on the issues of frequency converters and soft starters,

- after-sale support.

Examples of implemented projects:

Manufacture of MCC cabinets for MCC Norilski Nickel OJSC

Under the project of reconstruction and retrofitting of the Talnakh Concentrating Mill with increase of production capacity up to 16 mln. tons of ore, Main complex, 1st launch facility KTP-22, KTP-23, KTP024 implemented by MCC Norilski Nickel OJSC, BPA has performed a range of works on supply of electric motor control cabinets of MCC type:

- Development of design documentation for low-voltage package modules of MCC type

- Manufacturing of nr. 19 MMC cabinets completed with frequency converters with power capacity of 22kW to 312kW

A challenging task of active electrical equipment location (electrical drives, switch over devices, filters) in the cabinets with reduced clearance having IP54 enclosure class was solved by BPA designers.

The frequency converters of ACS800 type, filters and switch over devices manufactured by ABB were implemented in the project.

Supply of 0.4kV and 6kV frequency converters for MCC Norilski Nickel OJSC

Within the framework of implementation of the projects of reconstruction and retrofitting of the facilities at MCC Norilski Nickel OJSC, BPA has performed the supplies of 0.4kV and 6kV electric drives:

- supply of 0.4kV FC of ACS800 type, spare parts made by АВВ (48 pcs.)

- supply of 6kV FC of PF7000 type, spare parts made by Allen-Bradley (2 pcs.)

Turn-key implementation of PF7000 type frequency converters (3.3kV; 3.8MW) for Gazpromneft-ONPZ OJSC

In the course of implementation of the project “PPE. Izomalk-2. Retrofitting. Replacement of TsK-1 frequency converter” for Gazpromneft-ONPZ OJSC, city of Omsk, BPA has performed turn-key implementation of the variable speed drive of PowerFlex7000 series for a motor, 3300 V, up to 720 A (3600 kW / 4750 h.p.), air cooled, completed with bypass switching-on system.

The scope of the performed works included:

- development and justification of a technical solution

- designing (sections Architectural and Civil, Heating, Ventilation and Conditioning, Power Electrical Equipment, Controls and Instrumentation)

- expert examination of the project in respect to fire safety

- supply of equipment and materials

- construction, installation, commissioning and start-up works

- commissioning of the unit

- training of the Customer’s specialists

According to the manufacturing technique, ontinuous operation of the electric drive is provided for 4 years. This is the first implementation of this drive in Russia.

Main scope of the supplied equipment:

- PowerFlex7000 drive for compressor motor, 3300 V, up to 720 A (3600 kW / 4750 h.p.), air cooling, made by Allen-Bradley

- 6kV switchgear for FC connection, motor to FC and network based on the bypass diagram, implemented on the compartments of 1512DM and 1512M types, made by Allen-Bradley

- insulating transformer 5000 kVA, 6.0-3.3 , “non-oil” type

- spare parts

- conditioning system

APCS of automized stops/parkings (6 stops)

ACS is designed for the purpose of controlling a motorized car parking. The car parking is integrated into an office building, on the underground premises, and structurally consists of:

- an entrance zone, equipped with automatic entrance doors and side-hinged glass doors to restrict access to the elevator shaft. Also the operator’s room is located in the entry area;

- the shafts, where the elevator is located, equipped with a rotary device with the ability to turn a tray on the elevation of “- 3.000”, and fitted with extendable stops, by which its structure is mechanically fixed on the shift wall corbel in the entrance area and on each storey;

- Three horizontal (one above the other) circles. In the center of each circle the guides are installed for horizontal movement of carts along the compartments with trays for storing the cars; the compartments are located to the left and to the right of the carts travel area. Carts are equipped with manipulators and hydraulic systems that move the tray from the storage compartment on the cart, and then on the elevator and in the opposite side.

The system completes the following tasks:

- operation of separate mechanisms in manual mode, using local controls;

- operation of the system in operational mode using commands from the operator panel. The system performs single semiautomatic operations by means of various mechanisms of the system;

- operation of the system in automatic mode by selection of one of three sub-modes, aimed at different intensity of parking and delivery of the cars (sub-mode "morning" - frequent parkings and rare delivery, "day" - the same number of parkings and deliveries, "evening" - rare parkings and frequent deliveries);

- automatic selection of a parking compartment from a number of not occupied compartments with optimization of time for putting into compartment.

Technological subjects of control:

- system of issuance and collection of proximity cards;

- entrance door with traffic light;

- elevator with turning table and extendable stops;

- cart of the 1st circle with manipulator and hydraulic system;

- cart of the 2nd circle with manipulator and hydraulic system;

- cart of the 3rd circle with manipulator and hydraulic system;

- trays in the parking compartments (33 pcs.).

Implemented equipment and software:

- there was used in the project the equipment and software of Rockwell Automation – programmable logic controller Allen-Bradley series MicroLigic 1500, graphic panel Allen-Bradley series PanelView Plus 700, project for panel is developed by means of the software RSView Studio;

- frequency converters manufactured by Danfoss, series FC302 for vertical movement drive, and FC301 series for mechanism drives of each circle, as well as the drive of turn-table;

- inductive sensors, optical and limit stop switches, power switching equipment, control and alarm means – manufactured by Phoenix Contact;

- enclosures of cabinets and operator’s panel – manufactured by Rittal.

Low-voltage package modules for electrical energy distribution and control of electric drives

The project included assembling of low-voltage package modules of gas desulfurization of the installed capacity:

- Board 1Shch – 772 kW,

- Board 2Shch – 285 kW.

The low-voltage package modules include: terminal panels, distribution panels, control panel board of eclectic drives. When assembling the low-voltage package modules in accordance with the project the equipment made by ABB was used.

Control and measuring instruments and field equipment

Section Control Instrumentation
Name of job Engineering of Field Equipment
Description

Department of Control Instrumentation and Field Equipment fulfils the tasks of engineering, selection and supply of control instrumentation, shutoff and control valves, auxiliary electrical apparatus and base constructions.

Employees of the Department of Control Instrumentation are high-qualified specialists having experience in implementation of projects of field equipment intended for wide range of industrial sectors. Principal directions of the activity include implementation of projects and supply of equipment for Oil and Gas Industry of Russia and CIS countries.

BPA LLC is an official distributor of the leading manufacturers of control instrumentation, shutoff and control valves:

 

Invensys, Krohne, Emerson, Endress&Hauser, Honeywell, Siemens, Yokogawa, Masonelian, Drager, Daily Telemetrics, Wika, Jumo, Тесей, Tescom, DK-lock, Seba Hydrometrie, Flowserve, Rotork

Automated control system, Emergency protection and Fire-prevention automatics

Development and implementation of DCS, ESD and fire automatics control systems

The proposed technical solutions are built on the commercially available hardware and software of both, domestic and foreign manufacturers, having passed the tests and certified by the appropriate documents (certificates, permits for use in Russia):

  • Certificate of Conformity issued by GosStandart of Russia;
  • Pattern Approval Certificate of Measuring Instruments issued by GosStandart of Russia;
  • Certificate of Explosion Proofness of Electric Installation for the equipment installed in explosive hazardous zones;
  • Permit of Rostekhnadzor (Gosgortekhnadzor) for use in the Russian Federation.

1. Engineering of Control Systems

  • development of technical and commercial proposals for engineering of APCS systems;
  • development of feasibility studies for APCS system implementation;
  • development of engineering designs of APCS systems;
  • development of engineering and operational documentation for APCS systems.

A technical and commercial proposal for APCS system developed by the Company’s specialists includes:

  • detail description of proposed technical solutions;
  • specification of equipment;
  • calculation of cost and duration of work stages;
  • structural diagram of the proposed APCS system.

Any technical and commercial proposal is prepared after provision of the basic data by the Customer.

At the stage of design, the list of the developed documents and their completeness are determined in accordance with GOST 34.201-89 “Types, Sets and Indication of Documents for Automated Systems Design”.

Approximate set of documents of a standard Technical working design.

Section "General Systemic Documentation"

  • List of main contractors.
  • Quantity sheet of engineering design.
  • Explanatory note.
  • Scheme of functional structure.

Section "Hardware"

  • Description of hardware components set.
  • Explanatory note.
  • Quantity sheet of equipment.
  • Structure scheme of hardware components set.
  • Connections wiring diagram.
  • External connection diagram.
  • Drawing of hardware installation.
  • Certificate of Conformity of hardware components.
  • Pattern Approval Certificate of Measuring Instruments.
  • Permit of Gosgortekhnadzor for use in the Russian Federation.

Section "Software and Information Support"

  • Description of software.
  • Explanatory note.
  • Quantity sheet of software.
  • List of input signals and data.
  • List of output signals.
  • List of output documents.

Approximate content of the Operational Documentation of the project:

  • List of Operational Documentation.
  • Program and methods for trial tests.
  • Program and methods for acceptance tests.
  • Passport of the system.
  • System logbook.
  • User manual.
  • System engineer manual.
  • Operational manual for hardware components set.

Development of engineering documentation is made on the basis of the following regulatory documents:

  • GOST 21.101-97 "Main Requirements for Design and Working Documents";
  • SNiP 11-01-95 "Instructions on the Procedure of Development, Coordination, Approval and Composition of Design Documentation of Enterprises, Buildings and Structures”;
  • GOST 34.003-90 "Information Technology. Set of Standards for Automated Systems. Automated Systems. Terms and Definitions";
  • RD 50-34.698.90 "Methodology Instructions. Information Technology. Set of Standards for Automated Systems. Requirements to Documents Content";
  • EIC "Rules for Installing Electrical Facilities. Sixth Edition, Moscow, 1998";
  • GOST 12.1.030-81.OSSS "Electric Safety. Protective Conductive Earth, Neutralling”;
  • GOST R 50571.15-97 "Electrical Installations of Buildings. Selection and Erection of Electrical Equipment ".

2. Development of APCS Application Software.

Specialists of the Company develop each specific project on the basis of the following basic principles:

  • Hardware and software used are standard-based and manufactured by the leading manufacturers, steadily operating in the market, having representative offices in Russia and ensuring high quality support to purchasers of their products.
  • Openness of technical solutions making it possible to use integrally the hardware and software of different manufacturers.
  • Preparation of detail engineering documentation, training of the enterprise’s staff, if necessary, to provide further opportunities for the system development by the customer’s specialists efforts.
  • Effective interaction with the APCS system existing at the enterprise. Moreover, if the available APCS is developed on the basis of standard open approaches, it is possible to provide its maximum close integration with the new information system – to the extent of retransmission of control commands from the upper level of the system to the level of sensors.
  • Capability of quickest possible implementation of APCS systems, particularly, due to the fact that technical solutions of the system are modular and strictly structured.

Automated Metering ASCAPC, ASEPTRK, AMIS EPFA

Automated Metering Systems (Automated System for Commercial Accounting of Power Consumption (ASCAPC)/Automated System of Electric Power Technical Record-Keeping (ASEPTRK)/Automated Measuring and Information System for Electric Power Fiscal Accounting (AMIS EPFA))

Automated systems of commercial and technical accounting of electric energy and energy resources (ASCAPC/ASEPTRK/AMIS EPFA) are becoming an obligatory condition of effective operation of electric power systems and plant facilities at all stages, from production to consumption.

BPA provides a wide range of services on creation of turn-key automated metering systems:

- survey of facilities, proposal of effective technical solutions,

- designing,

- completing with components and supply of equipment, computing machinery and software,

- construction and installation works, commissioning and startup works on installation of electric energy meters and other energy resources meters,

- implementation of automated metering systems of electric energy (AMIS EPFA/ASEPTRK) and energy resources on the basis of “Energoserver” ASCAPC software package,

- works on certification of systems as measuring instruments for compliance with the requirements of the wholesale market.

    

The key product of BPA in this field of activity is “Energoserver” ASCAPC software package designed for creation of advanced automated accounting systems of electric energy and energy resources of different classes and sizes.

Core capabilities:

- scanning of various types of digital metering units;

- support of a wide range of wire and wireless communication channels;

- time synchronization in metering units;

- convenient and clear configuration tool for the data collection system;

- on-line monitoring of metering units status;

- flexible system of scanning time-table;

- balance consolidation, calculation and monitoring of permissible imbalance;

- preparation of data exchange patterns as per standards of the wholesale market of electric energy;

- remote switch off of the load;

- data exchange with adjoining systems via OPC protocol;

- flexible connection mechanism of user’s reports;

- various databases support - Oracle, MSSQL, PostgreSQL.

“Energoserver” ASCAPC Package supports the following types of metering instruments:

Electricity meters:

- Ryazan State Instrument-Making Enterprise (SET and GAMMA);

- Nizhny Novgorod Plant named after M.V. Frunze (SEB-1ТМ.02, SEB-2А, PSCh-3ТА.07, PSCh-4ТМ.05, SET-4ТМ.03);

- Energomera Concern (СЕ102, CE6850М, СЕ301);

- Incotex Scientific and Production Company (Mercury 203.2Т, 233АРТ etc.);

- Elster Metronica (А1600, А1800);

- Matritsa (NP515, NP 545 etc.).

Measurers and flow meters:

- SovTIGaz (Superflow);

- Logika Scientific and Production Firm (SPT, SPG);

- Globus (IRGA);

- Vympel Scientific and Production Firm (Hyperflow);

- Tekon Group of Companies (Tekon);

- Teplocom-Service М (VKT-7);

- Vzlyot (VZLYOT VRS);

- Intelpribor (MKTS).

Examples of implemented projects:

ASEPTRK for Karelski Okatysh OJSC

There was developed and implemented the system of automation of monitoring and metering process of vapour, compressed air, and naphtha residue and grid water.

ASCAPC for Stoilenski GOK OJSC

There was developed and implemented the complex system of metering of energy resources of the enterprise that included more than 60 measurement instruments of different manufacturers;

Modernization of APCS for Company “Polyarnoye Siyanie” LLC

There was developed and implemented the system of automated metering of the associated gas;

Modernization of AMIS EPFA for Municipal Unitary Enterprise “Voronezh Gorelectroset”

There was implemented a large-scale project for automation of electric energy metering of Voronezh city consumers, including scanning of more than 1300 meters via GSM and GPRS channels.

The system of DC

Operating DC Voltage Systems (ODVS)

Modern system of electric power supply of power engineering facilities and industrial enterprises can not be developed without operating DC voltage systems (ODVS).

Prime area of ODVS application is uninterruptible (autonomous operation during not less than 30 minutes) electric power supply of medium- and high-power facilities in power production (110-750kV substations), oil and gas sectors, industry, communications and telecommunications facilities.

An urgent need to modernize and refit the electric energy facilities, as well as to commission new capacities requires reliable systems of uninterruptible power supply that meet the present-day operating requirements. Main partner of BPA in ODVS field is a world-wide leader, GUTOR company, a member of Schneider-Electric Group. The offered ODVS are certified in FGC UES and the Inter-Regional High-Voltage Grid Company, as well as they have GOST R certificates.

    

Standard components of ODVS offered by BPA include:

- rectifier chargers with capability to install ballasting arrangement at output,

- accumulator batteries (AB) with AB safety block,

- direct current board (DCB),

- standby lighting block (SLB),

- control current distribution cabinet (CCDC),

- insulation monitoring device of poles in network relative to ground,

- system of automated search of damaged insulation of poles in network relative to ground,

- detector of emergency processes and events (ODVS) (optional),

- monitoring and remote control device, and the means of giving signal of summarized fault in APCS,

- inverter installation with network bypass for power supply from ODVS of ac power consumers of special importance (optional).

Substation auxiliaries

The systems of substation auxiliaries ensure operation of substations providing internal consumers of substations with operating direct and alternating currents. Any breakdown (loss) of auxiliary systems causes shutdown of the whole substation, as well as serious problems during its subsequent putting into operation. So, at development of the systems of substation auxiliaries, one should be governed by selection of reliable and high-quality electrical equipment.

The solutions proposed by BPA for the systems of substation auxiliaries include:

- auxiliary power transformers,

- independent power supply source (as a rule, it is a diesel generator unit),

- medium-voltage switchgear,

- auxiliaries board (two or three inputs from ACB),

- operating DC voltage system:

  • full-rate ODVS including rectifier chargers, accumulator batteries and dc boards,
  • or complex of ODVS and auxiliary services cabinets for small substations

- switch gear cabinets and operating current panels (control current distribution cabinets, DC panels)

- automated system for integration of auxiliaries into APCS of substations.

    

Any offered equipment is certified in accordance with the requirements of the Customs Union, meets the requirements of GOST R, as well as it is certified in FGC UES and in the Inter-Regional High-Voltage Grid Company.

BPA renders full range of services for substation auxiliaries, namely:

- qualified selection of equipment, proposal of effective engineering solutions,

- development of requirement specifications and detail designs,

- manufacture of certified auxiliaries boards, DCB, auxiliary services cabinets, control current distribution cabinets, DC panels and complex ODVS,

- completing with components and supply of auxiliaries equipment,

- installation and construction works, erection supervision, commissioning and start-up works,

- retrofit and modernization of out-of-date equipment,

- after-sale support.

Uninterrupted power supply system

Industrial uninterruptible power supply and uninterruptible power supply units (UPS and UPSU)

Industrial uninterruptible power supply and uninterruptible power supply units (UPS and UPSU) are designed for power supply of three-phase and single phase essential service requiring high-quality power voltage and placing high requirements to the electric power supply stability.

Main partner of BPA in industrial-grade UPS is the world-wide leader in the field of uninterruptible power supply systems – GUTOR company, a member of Schneider-Electric Group. GUTOR is engaged, first of all, in design and development of its own technologies for high-efficiency power protection. The industrial-grade interruptible power supply units produced by GUTOR meet the requirements of such industries as oil and gas, petrochemical and chemical industries and production and transmission of electrical energy.

UPS of GUTOR grade are designed for output power of 5 to 220 kVA, supported by all commonly used input and output voltages and frequencies. At the Customer’s request, manufacturing of any customized UPS of higher capacity is possible. To improve reliability and efficiency, UPS modules are connected in parallel (2 to 9 units). A wide range of additional options expands the functionality of industrial grade UPS according to the variety of the Customer’s demands.

The GUTOR technology satisfies basic requirements of essential service of uninterruptible electric power supply:

- performance flexibility, maximum safety and reliability of systems;

- double conversion;

- parallel redundancy;

- active load division;

- modular design;

- accumulators of closed and hermetically sealed types completed with genuine parts of HAWKER GmbH (Germany).

    

The result of BPA’s work is tern-key supply of up-to-date complex systems of uninterruptible power supply, own monitoring and control systems that are linked with general APCS system of the enterprise.

Frequency converters and soft starters

Frequency converters (soft starters) or variable speed drives (VSD) are used for automation of installations with electric motors, motor speed control, energy-saving, and help to reduce operating costs and deterioration of operating mechanisms.

Soft starters make it possible to have а smooth (reduced-current) start and deceleration of electric motors.

The greatest economic effect is achieved due to use of frequency converters for pumps and fans in case of relatively large extent of motor speed control. Use of frequency converters in the systems of ventilation, conditioning and water supply have actually become a standard.

Today, the market offers a variety of modifications of frequency converters and soft starters of various manufacturers. BPA relies on high quality drives produced by the world-wide leaders of this direction:

- Rockwell Automation (Allen-Bradley),

- ABB, Siemens,

- Danfoss,

- Schneider-Electric.

    

Supply of converters made by other manufacturers is possible at the Customer’s request.

BPA offers full range of services for implementation of frequency converters and soft starters for voltage rating from 0.4kV to 10kV:

- integrated survey inspection of electrical installations,

- development and justification of technical solutions,

- development of requirement specifications,

- designing,

- expert examinations of projects,

- justification of projects and electrical installation in the supervision bodies

- manufacture of certified cabinets with frequency converters and soft starters (low-voltage package modules of MCC type),

- delivery of electrical equipment to any destination point within the country and abroad,

- construction and installation works, erection supervision, commissioning and start-up works,

- advisory on the issues of frequency converters and soft starters,

- after-sale support.

Power equipment for electrical energy distribution

With the growth of electrical energy consumption, and in the context of strengthening of the requirements to the quality and reliability of electric energy distributions systems, there is a critical need for implementation of up-to-date substation equipment (transformers, package substations, distribution gears, switching devices, metering units). Modernization of existing substations makes it possible to ensure sustainable electric power supply, to increase the reserve power for further extension of consumers.

BPA acts as an integrator of package solutions for implementation of advanced distribution electrical equipment produced by the leaders of this direction:

- ABB,

- Siemens,

- Eaton,

- Schneider-Electric,

as well as produced by domestic manufacturers.

    

BPA offers full range of services for implementation of 0.4kV to 220kV electrical power equipment (power and measuring transformers, power-factor correction units, distribution gears, package/block-modular/concrete transforming substations, electrical supply block-boxes with low-voltage package modules etc.):

- integrated survey inspection of electrical installations,

- development and justification of technical solutions,

- development of requirement specifications,

- designing,

- expert examinations of projects, justification of projects and electrical installations in the supervision bodies

- manufacture of certified low-voltage package module cabinets,

- completing with components and supply of electrical equipment and materials,

- integration of power electrical equipment into APCS of substations and enterprises

- construction and installation works, erection supervision, commissioning and start-up works,

- electrical installation tests with reporting according to the forms established by Rostekhnadzor,

- training of operating and maintenance personnel in operation of new equipment,

- retrofitting of electrical equipment,

- after-sale support.

Monitoring systems of power transformer equipment

Monitoring Systems (MS) of parameters of power transformer equipment, voltage rating 110-1250kV, are designed for continuous measuring and recording of critical parameters of transformers, autotype transformers and reactor coils while in operation. The present-day MS systems make it possible to detect any malfunction in the operation of power transformers and other equipment of substations in early stages of their occurrence, and, therefore, to take a decision on their elimination before any contingency. It does not only prevent any significant damage, but it cuts shutdown time, reduces expenditures for repairs and extends the service life of transformers.

BPA LLC is a representative and service partner of Energoavtomatizatsiya LLC (Zaporozhye) - a manufacturer of MS systems (Independent Monitoring Systems - IMS) of SAFE-Т type. BPA is engaged in promotion of SAFE-Т systems within the Russian Federation, it performs the licensed production, renders the services for installation and start up, warranty and after-sale support of SAFE-Т systems, as well as in-process control devices of gas and moisture contents in insulating oil of Calisto type made by Morgan Schaffer Inc, Canada.

The IMS functional capabilities include:

- continuous monitoring of power transformer equipment status in on-line mode;

- timely informing of operating staff for the purpose of control and regulation of equipment operation modes and timely taking of necessary actions at any pre-fault conditions, as well as provision of information for analysis of emergency conditions;

- analysis of power transformer equipment based on archived parameters and events accumulated for the whole period of operation.

The SAFE-Т systems and Calisto instruments are certified in FGC UES.