Ker Eng English Ver

KER-ENGINEERING GROUP OF COMPANIES

Moscow

Kirov

Perm

Atyrau

Aktau

Volgograd

Saratov

Penza

Saransk

Voronezh

Ulyanovsk

Samara

Orenburg

Ufa

KazanPerm

Izhevsk

Nizhny

Novgorod

Rostov-on-Don

Kurakhovo

GEOGRAPHY OF CUSTOMERS

www.ker-eng.comwww.ker-eng.com

Verkhny Tagil

Tyumen

Chelyabinsk

Barnaul

Tomsk

Ekaterinburg

Novosibirsk

Abakan

Aksu

Ekibastuz Ust-

Kamenogorsk

Almaty

4CONCERNING THE COMPANY

Introduction ..........................................................................................................................................................7

Structure .................................................................................................................................................................8

Fields of activities..............................................................................................................................................9

Quality ................................................................................................................................................................... 10

Our customers ..................................................................................................................................................11

Partners .................................................................................................................................................................12

Training of Specialists .................................................................................................................................. 13

DESIGNING AND SUPPORT OF CONSTRUCTION

Preliminary design study ............................................................................................................................ 17

Field of activities ............................................................................................................................................. 18

Leading projects ............................................................................................................................................. 20

INDUSTRIAL AUTOMATION

Field of activities ............................................................................................................................................. 25

Standard solutions ......................................................................................................................................... 26

Leading projects in the field of industrial automation ..............................................................36

ELECTRICAL ENGINEERINGCompetences of electrical direction ................................................................................................... 41

Leading projects in the electrical direction ..................................................................................... 42

ENERGOTECHNOLOGICAL AUDITEnergotechnological audit ........................................................................................................................49

Leading projects ............................................................................................................................................58

Experience of international projects ..................................................................................................59

PRODUCTION

Production capacities ..................................................................................................................................63

REFERENCE LIST 71

CERTIFICATES AND PERMITS 83

TABLE OF CONTENTS

CONCERNINGTHE COMPANY

Engineering that creates advantages6

Management Company KER-Holding

ENGINEERING SECTION

KER-Engineering

KER-AvtomatikaKER-Naladka

TatNIPIenergopromEngineering Centre Energoprogress

KERKER-Montazh

Laying pipelines and oil pipelinesKER MEZAPMK-23

CONSTRUCTION AND INSTALLATION SECTION

Branch off icein Turkmenistan

Branch off ice in the Hashemite Kingdom of Jordan

Branch off icein Moscow

Branch off ice in Republicof Kazakhstan

Electrical Plant EnergoInvest Sarajevo (Republic of Srpska, Bosnia

and Herzegovina).

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Let me bring to your attention a group of companies KER-Engineering that is capable of solving engineering problems of diff erent complexity. The main pro le of the company is integrated engineering services in power and production sectors.

KER-Engineering is more than1000 quali ed experts.

KER-Engineering is more than700 implemented projects.

Advantages of cooperation with us are:Experience and reputation: The Com-

panys potential is based on specialists who have more than 25-30 years of work experi-ence in the engineering eld.

Currently, we have completed more than one hundred major projects, most are at strategic sites: Combined Heat and Power Plants (CHPs), State District Power Plants

(SDPPs), Hydraulic Power Plants (HPPs), etc.Quality of our work: Services performed

with a high degree of professionalism, timely and quality service, effi ciency - all this is a business card of KER-Engineering.

Companies from Russia, the USA, Germa-ny, France, China, the Ukraine, and Belarus are among our partners.

Developments of our company has re-ceived recognition from the customers not only in Russia, but also in countries near and far abroad.

Our integrated solutions:Group of companies KER-Engineering

provides a wide range of engineering solu-tions - from design and survey works to ser-vice maintenance. We off er more than 100 kinds of services, a number of projects is carried out on a turnkey basis.

Find detailed information on our compe-tences in the sections of this catalogue and at our web-site.

Director General of KER-EngineeringValery Arapov.

DEAR COLLEAGUES!

INTRODUCTION

Management CompanyKER-Holding LLC

www.ker-holding.ruKER-Engineering LLC

www.ker-eng.com

We are always open to all forms of cooperation and will seriously consider your individual needs!


STRUCTURE

KER-Engineering is a group of companies that specialize in providing integrated services in the eld of engineering.

KER-Engineering is a part of Management Company KER-Holding (www.ker.ru) that per-forms the full cycle of project management (EPC/ EPCM-contractor) and implements integrated solutions in construction and maintenance of industrial facilities with installation of high-tech-nology equipment in the power sector, petro-chemical and oil re ning, metallurgy, machinery building, oil and gas industry in Russia, CIS and abroad.

TatNIPIenergoprom Branch performs design and survey works and engineering support ser-vices for construction.

KER-Avtomatika Branch is automation of tech-nological processes and production, electrical engi-neering, production of equipment.

Engineering Centre Energoprogress Branch is integrated engineering support and maintenance of heating and electrical equipment for TPP.

KER-Naladka Branch is commissioning works and operational tests of power equipment and ex-amination of technical devices.

KER-Engineering Group is based on the follow-ing principles:

Uni ed technical policy; Flexible project management system; Maximum independence of the branch-

es.

Electrical Plant EnergoInvest (Bosnia and Herze-govina)

INTEGRATED ENGINEERING SERVICES

KER-Engineering top management

TatNIPIenergoprom Branch

Integrated designing in in power and production

sectors

Industrial automation. Rehabilitation of electrical

equipment

Technical audit. Tests and diagnostics of equipment.

Industry examination. Commissioning.

Performance adjustment.

KER-Avtomatika BranchEngineering Centre

Energoprogress BranchKER-Naladka Branch

Electrical Plant EnergoInvest (Bosnia and

Herzegovina)

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FIELDS OF ACTIVITIES

Preliminary design survey in power and production sectors

Examination (technical condition assess-ment) of a facility including examination of industrial safety of technical equipment, buildings and facilities, examination of mod-ernization and redesign projects. Develop-ment of investment programs, development of technological, environmental, economic and nancial documentation for implemen-tation of projects for industrial modernization and rehabilitation.

Integrated designingDevelopment of projects (thermal power

plants, combined heat and power plants, boiler houses, heating networks, and power supply of industrial enterprises, agricultural facilities, public buildings and facilities) as well as development of heat and power sup-ply schemes for industrial facilities, cities and towns.

Construction supportPreparation and processing of initial data

for designing and rehabilitation of facilities, technical support of the project phase (su-pervise of development of design and esti-mate documentation, its coordination with customers and in regulatory authorities), ar-rangement of technical supervision.

Integrated industrial automationFull range of services for development and

implementation of automated process con-trol systems (DCS): site survey, development of project documentation and engineering solutions, installation, commissioning, service maintenance.

Rehabilitation of electrical equipmentRehabilitation and construction of 6 - 220

kV class substations; rehabilitation of electri-cal equipment at generating stations, repair of 0.4 - 220 kV class power electrical equip-ment, designing and implementation of DCS for electrical equipment, power supply DCS (remote control, automated measuring and information system for electric power scal accounting).

Integrated energotechnological audit of enterprises

A range of services that allow to estimate eff ectiveness of industrial processes, con-sumption and transfer of heat and power en-ergy as well as develop measures to enhance effi ciency of power equipment and related processes.

Electrical engineeringA range of services in the electrical area:

rehabilitation and construction of 6 - 500 kV class substations; rehabilitation of electri-cal equipment at generating stations, repair of 0.4 - 550 kV class power electrical equip-ment, DCS for electrical equipment at substa-tions, diagnostics and technical inspection of electrical equipment.

Production of equipmentProduction of software and hardware

packages, control cabinets, frequency trans-formers, soft starters, complete pumping sta-tions, sensors, valves, etc.


QUALITY

Qualitative performance of works is the leading principle of KER-Engineering, a formula of the com-panys competitiveness in the domestic and foreign markets.

One of the main priorities is creating a team of highly quali ed specialists.

The Companys backbone is made up of special-ists who came from KazEnergoNaladka Company (Kazakhstan) and the Volga branch of VNIPIenergo-prom OJSC. Experience of these specialists in the eld of engineering is 20-25 years, many experts are Doctors of Science.

Quality policy key provisions:

Operation in the quality control systemThe Companys quality management system has

been certi ed for compliance with ISO 9001:2008. Quality management system was preceded by the considerable preparatory work. A set of standards was created de ning common rules of works, crite-ria for measuring the quality of works at all stages of production were developed, provisions on divisions were completely revised.

Commitment to international quality standardsOur Company pays great attention to develop-

ment and improvement of quality of services. The Company has a number of licenses and certi cates for implementation of engineering services.

Individual approach to customerWe off er integrated solutions that meet the cus-

tomers needs, fully tailored to a particular facility.

Modern, effi cient technologies and materialsKER-Engineering constantly monitors the mar-

ket for new technologies, actively implements the most eff ective of them in its activities, is engaged in its own developments.

Involvement of staff Every employee of the Company, from the

worker to the Director General, is responsible for the quality of their work. KER-Engineering pursue a policy which aim is provoke interest of each em-ployee in the results of their work as well as sum-mon creative abilities of employees.

Advanced trainingKER-Engineering attaches great importance to

training and professional development of its em-ployees including training abroad.

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OUR CUSTOMERS

KER-Engineering has an extensive experi-ence in development and implementation of engineering projects in Russia as well as in CIS and foreign countries: Kazakhstan, Belarus, the Ukraine, Pakistan. Quality of works is con- rmed by the positive reviews of customers.

Russia Research and Production Enterprise Bio-

techprogress CJSC; The Defense Ministry of the Russian Fed-

eration; Bashkirenergo OJSC; VNIPINEFT OJSC; Kazancompressormash OJSC; KAMAZ OJSC; Mosenergo OJSC; Nizhnekamskshina OJSC; Wholesale Generating Company-1 OJSC; Wholesale Generating Company-2 OJSC; Wholesale Generating Company-3 OJSC; Wholesale Generating Company-4 OJSC; OZNA OJSC; RusGidro OJSC; Territorial Generating Company-1 OJSC; Territorial Generating Company-4 OJSC; Territorial Generating Company-5 OJSC; Territorial Generating Company-6 OJSC; Territorial Generating Company-11 OJSC; Territorial Generating Company-16 OJSC; Generating Company OJSC; Bashkir Generating Company LLC; Yenisei Territorial Generating Company

OJSC (Territorial Generating Company-13); Fortum OJSC; Orenburg Territorial Gener-

ating Company OJSC; Grid Company OJSC; FEZ Alabuga.

CIS and foreign countries Ekibastuz SDPP-1 LLP (Kazakhstan); Ekibastuz SDPP-1 (Kazakhstan); Eurasian Energy Corporation JSC, Aksu TPP (Kazakhstan); MAEK-Kazatomprom LLP, CHPs-1, 2, 3

(Kazakhstan, Aktau); Republican unitary enterprise Grodno-

energo, Lida CHP (Belarus); Vostokenergo LLC, Kurakhovo TPP (the

Ukraine); Najibia TPP (Iraque); Metallurgical Plant Pakstil (Pakistan); Fria CHP (Guinea); CHP at the Oil

Re nery Plant (Republic of Yemen); United Power Company JSC (Kazakhstan); AlES JSC (Kazakhstan); AES Ust-Kamenogorsk CHP JSC (Ka-

zakhstan).

Oil and Gas Industry Oil Company Rosneft OJSC; Lukoil

OJSC; Mid-Volga Transnefteprodukt OJSC; Novosibirskneftegaz OJSC (TNK-VP); Nizhnekamsktekhuglerod OJSC. Kazanorgsintez OJSC; Nizhnekamskneftekhim OJSC; TAIF-NK OJSC; TANEKO OJSC; Tatneft OJSC;

Housing and public utility sector Moscow United Energy Company OJSC; Chelnyvodokanal CJSC; Municipal Unitary Enterprise Yelabuga-

Vodocanal; Naberezhnye Chelny Heat Distribution

Company OJSC; Kazan Heat Distribution Company OJSC; Almetyevsk heating networks OJSC.

Machine-building industry Sollers; Kazan Helicopter Plant OJSC; Central automobile repair factories.

Metallurgy Novolipetsk Metallurgical Combine OJSC; Metallurgical plant (Myanma-Burma Un-

ion)

Food processing industry; Tatspirtprom OJSC; Zainsk sugar OJSC; Chelny-Broiler LLC.


PARTNERS

In the eld of design and con-struction supervision:

Ural-TEP Design and Engineering Center CJSC (Ekaterinburg);

OPTEN Limited CJSC (Moscow); Teploelectroproekt Institute (Nizhny

Novgorod); Belarusian Foreign Energy Project Com-

pany; Biotechprogress Research and Production

Enterprise (St. Petersburg); Teploelectroproject (Lviv, Ukraine) LLC; Zarubezhenergoproekt LLC (Ivanovo); Energostroyoptik OJSC (Moscow); Kazan Electroproject LLC (Kazan); Scienti c Production Association for Re-

search and Design of Power Equipment named after Polzunov OJSC (St. Petersburg);

Krasny Kotelshchik OJSC (Taganrog); Podolsk boiler plant CJSC; Azimut Scienti c and Production Centre LLC

(Kazan); KamTISIZ OJSC (Naberezhnye Chelny); BelNIPIenergoprom Republican Unitary

Enterprise (Minsk);

In the eld of industrial automation:

Global manufacturers Siemens Emerson Metso Yokogawa Danfoss Schneider Electric ABB

t Domestic manufacturers. Krug Research and Production Company Volmag CJSC Vibrobit Scienti c Production Association Biotechprogress Research and Production

Enterprise CJSC; EKRA Research and Production Enterprise SOUTH-SYSTEM plus OJSC ARGO Research and Development Centre VZLYOT CJSC ITV

In the eld of reconstruction of electrical equipment:

Siemens; EKRA Research and Production Enterprise ABB; Schneider Electric.

In the eld of energy process audit: MP Diagnost CJSC (Moscow); Pergam Company CJSC (Moscow); Priborostroitel Plant CJSC (St. Petersburg); Vector Scienti c and Production Company

CJSC (Moscow); ELNAP LLC (Moscow); DIAKS LLC (Moscow); Electrical Systems LLC (St. Petersburg) and

others.

Engineering companies (EPM, EPC-Contractors) Management Company KER-Holding LLC INVENT LLC 4-Sibkotes OJSC Sealtek CJSC Ural Power Engineering Centre OJSC

Design organizations VNIPIenergoprom Association OJSC VNIPIneft OJSC TatNIPIenergoprom LLC VNIIR OJSC All-Russian Research Institute of Metrology

named after D.I.Mendeleyev FSUE

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TRAINING OF SPECIALISTS

Advanced trainingEmployees are trained in training cent-

ers of Siemens, Emerson. There is a training center on the basis of KER-Engineering that specializes in staff development. We have experience of training specialists from Arabic countries.

The Company provides training and certi -cation of specialists in several areas:

Setting up automatic regulation systems of thermal power processes;

Process protections and interlocks;The principle and structure of TPP and oth-

ers.

Cooperation with higher education institutionsInteraction with higher education institu-

tions for target staff training is allocated to one of the strategic directions of KER-Engineering. The basic engineering staff of the Company consists of graduates of leading Russian uni-versities:

Moscow Power Engineering Institute (Tech-nical Institute),

Kazan State Power Engineering University, Kazan State Technical University named af-

ter A. N.Tupolev, Kazan State Technological University, Tomsk Polytechnic University, Ivanovo Power Engineering University.

Our main partners are:Kazan State Power Engineering UniversityAnnually, students of this University under-

take an internship at the enterprises KER-Av-tomatika, Engineering Centre Energoprogress, TatNIPIenergoprom. Upon completion of the practice, most part of students remain in the Company and successfully perform engineer-ing tasks. The contract of target preparation of specialists was signed with Kazan State Power Engineering University.

KER-Avtomatika Company takes an ac-tive part in technical equipping of training and laboratory facilities of Process and Produc-tion Automation Department of the Kazan

State Power Engineering University. 3 modern specialized training facility for settings of au-tomatic control systems for boiler supply and superheated steam were presented for the Department. A specialized laboratory was ar-ranged there. It is planned to arrange a com-bined training centre.

Kazan State Technical University named af-ter A. N.Tupolev

Interconnection of KER-Engineering Company and Kazan State Technical Univer-sity named after A. N.Tupolev for target prep-aration of specialists is implemented in the framework of the contract signed between KER-Holding and Kazan State Technical Uni-versity named after A. N.Tupolev. Students directed from KER-Engineering enterprises, along with the traditional training courses, receive education on additional targeted training programs according to the activities of their enterprises. The work on the com-bined development of modern computer de-sign technologies started.

Kazan State Academy of Architecture and Construction

The Academy students undertake an an-nual internship in the subdivisions of KER-Engineering. After graduation a number of graduates nd employment in the company.

Engineering that Engineering thatcreates advantagescreates advantages

DESIGNINGAND SUPPORTOF CONSTRUCTION

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Implementation of General Designer func-tions.

Development and support of investment projects on production reconstruction and

upgradingPreliminary design survey facility tech-

nical and economic audit which helps to esti-mate effi ciency of processes for the purpose of optimization and improving of energy re-source use effi ciency, reliability of equipment and technical installations.

Following the audit completion, the cus-tomers are off ered with:

plans of low-cost measures such as: ad-justment and optimization of equipment op-erational modes, implementation of optimal technologies and engineering solutions;

investment projects on upgrading the main process and power equipment;

feasibility study of investment programs; calculation and assignment of residual

operation life; consulting activities on support of invest-

ment projects; business plan, development of process,

environmental, economic and nancial docu-mentation for the project.

Support services for investment projects consulting and supervision activities:

preparation of contract documentation; bid arrangement; evaluation of proposals and drawing up

recommendations for their implementation; contractor selection and contracting for

the project; inspection of the project implementation,

quality management; management of equipment supply and

installation; acceptance testing, technical conclusion -

the facility acceptance act; commissioning and performance adjust-

ment work; facility personnel training; development of

operational documentation; development of process maps; provision of conditions for occupational

safety and health.

Designing Preparation and approval of the design

assignment with collection of initial data need-ed;

Integrated design of a new construction facility, expansion and rehabilitation of power

facilities, power supply facilities of enterprises,

public buildings and constructions. Issue of de-

sign and estimate documentation;

Selection of subcontract organizations

including control over development of design

and estimate documentation;

Approval of design documentation in the

prescribed manner by the customer and regu-

latory bodies;

Expert examination of design and esti-

mate documentation.

Construction enginnering support

Obtaining and execution of initial data for

design of construction and rehabilitation facili-

ties;

Approval of design documentation includ-

ing obtaining a building permission;

Information and advisory services;

Arrangement of technical supervision,

participation in working committees;

Rendering services to foreign investors in

the design and construction under contracts.

Engineering surveys

Geodetic engineering surveys;

Geological engineering surveys;

Surveys of ground building materials;

Coordination of survey work.

PRELIMINARY DESIGN SURVEY


FIELD OF ACTIVITIES

Solution of design problems in the eld of: rehabilitation and upgrading of existing facili-

ties; construction of new facilities.

Types of design work: design of vibration control systems and me-

chanical values, turbine generating units and pump equipment;

integrated design of Electric Plants; integrated design of electric substations (volt-

age class up to 220 kV), open switchgears, closed switchgears, integrated switchgears;

design of engineering systems (water supply and sewage, heating and ventilation, power equip-ment and electric lighting, low-voltage systems, au-tomation and control);

electrical networks (Overhead transmission lines up to 500 kV);

design of off site yovers (high and medium pressure steam lines (up to 140 at), steam and fuel oil pipelines, pipelines of process systems, gas pipe-lines);

design of gas supply systems (natural gas main pipelines, gas distribution stations, gas control points, gas pipelines of distribution networks);

warehouses, storages, tank farms (of oil prod-ucts and solid fuel, refrigerators);

design of treatment facilities (waste waters from chemical water treatment facilities, process water, storm water);

Integrated design of heat sources: Combined Heat and Power Plants (CHPs based

on the cycles of steam turbines, gas turbines, com-bined cycle turbines);

small-scale CHPs (based on gas turbine and gas piston cycles);

heating networks;central heat supply stations;pump stations;boiler houses (district, quarterly, electric boiler

houses);development and design of power supply sys-

tems and heat supply systems at industrial enter-prises and settlements.

Special sections of project documentation: labor and working condition management; engineering and technical civil defense meas-

ures; protection of structures against corrosion; re alarm systems, re alarm systems and re

warning systems; alarm, surveillance and control systems; construction arrangement.

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Engineering staff The following departments were created

to solve tasks of design and engineering sup-port of construction:

Department of Integrated Design for large-scale facilities;

Department of Integrated Design for small-scale facilities;

Department of Integrated Design for backbone electric grids;

Technical Department provides general technical records, as well as activities aimed at improving quality of the developed design and estimate documentation and productivity of designers in accordance with the quality man-agement system (ISO 9001-2001).

A staff of experts is represented by the following specialties:

Chief Project Engineers; Chief Technicians; Leading experts in the directions:

Heat supply; Power supply; Construction and architecture; Development of environment

impact assessment and environmental pro-tection sections;

Design of re and alarm systems; Development of water supply

and sewerage sections; Design of gas distribution and gas

consumption systems; Design of primary chemistry sec-

tions;

Design of DCS; Engineering and survey work experts; Estimators.

Engineering capabilityUsing modern software products in design-

ers work signi cantly reduces the time for de-sign work, ensures high quality of work, ena-bles the uni cation of nodal solutions, allows to choose the best process solutions.

Currently, the following are successfully used: Compas 10, RastrWin 2.25.1.1, AUTOCAD 2007, Start 4.6, SCAD 11.1 (S128max), Funda-ment 12.3, Grand smeta 3, Astra-Nova2007.

Department for registration and documen-tation support is equipped with professional equipment (printers, copiers, scanners) for solving problems concerning production and reproduction of design and estimate docu-mentation, create backup documentation.

The geological and survey group is equipped with a multipurpose rig MBU-5-01, as well as all necessary materials for drilling works in various ways.


LEADING PROJECTS

Development of external power supply circuit for TANEKO Re nery and Petrochemical

Plant Complex (Nizhnekamsk)Customer: VNIPIneft OJSC (Moscow)Objective: Develop an optimal external power

supply circuit with connection to: existing mains power system of the Repub-

lic of Tatarstan; the projected circuit of internal electric pow-

er supply of the Complex; with due regard to the future growth of

electric loads and ow distribution in the adja-cent power center.

Calculations network modes on the various op-tions are made using software RastrWin 2.25. 1st stage without cogeneration installation, 2nd stage with due regard to cogeneration installation.

The best option was chosen, scopes of elec-tric network construction were determined with due regard to narrow places in Nizhnekamsk power district.

Upgrading (rehabilitation) of heat power plants including implementation of steam and gas

cyclesProjects with participation of our specialists: Construction of CCGT-230 at Zainsk SDPP

(replacement of Unit No.1 of CCGT consisting of: Alstom 170 MW gas turbine plant, Steam Turbine K-80 UMTZ);

Rehabilitation of Kazan CHP-1 including creation of CCGT (2nd stage of CCGT construc-tion including increase of capability from 50 up to 150 MW due to installation of 70 MW gas turbine plant and 30 MW steam turbine);

Expansion of Kazan CHP-3 including instal-lation of CCGT-190 (an unit of 2 Ansaldo 65 MW gas turbine plants and 60 MW steam turbine);

Construction of two CCGT-95 at Yelabuga CHP (Ansaldo 65 MW gas turbine plant and 30 MW steam turbine);

Information systems: the operative-infor-mation package and the automated control sys-tem (Naberezhnye Chelny and Kazan).

Construction and expansion of heat power plants and boiler houses, rehabilitation of heat-

ing circuitsProjects with participation of our specialists in

70-90-ies: Expansion of Oryol CHP:

) installation of Unit No.4 (the boiler - 500 t/h, the turbine -110 MW);

) construction of the boiler plant;) a peak boiler house including installation of

KVGM-180 hot-water boiler; Expansion of Arzamas CHP (two E-220 pow-

er boilers, two PT-25 turbines); Construction of Azino and Savinovo district

boiler houses with PTVM-180, KVGM-180 hot-water boilers, DE-25 steam boiler; Kazan Heating Networks;

Rehabilitation of a combined heat and pow-er plant at Kazan CHP-1 with the purpose of heat power increase.

Introduction of automated control systems of equipment operational modes

A project of introduction of Vibrobit-200, Vi-brobit-300 vibration and mechanical value con-trol system at turbines of branches of Tatenergo, Wholesale Generating Company-3, Southern Ural SDPP;

Introduction project of the automated pow-er control system at Wholesale Generating Com-pany-3, Southern Ural SDPP;

Introduction of test stands for internal com-bustion engines at Kamaz OJSC and the Ministry of Defense;

Introduction project of the dry ash removal system at Wholesale Generating Company-2, Troitsk SDPP.

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Upgrading and rehabilitation of water treat-ment and circulation water supply systems

Projects with participation of our specialists: Full-scale DCS for chemistry departments

at Kazan CHP-1, Kazan CHP-2, Kazan CHP-3, Zainsk SDPP, Nizhnekamsk CHP-1, Nizh-nekamsk CHP-2;

Upgrading of 3rd stage of water deminer-alization at Zainsk SDPP;

A project of enforcement and replacement of cooling tower building structure, ceiling, roof covering of the main building of Nizhnekamsk CHP-1.

Construction and rehabilitation of electric substations, open switchgears, closed

switchgearsProjects with participation of our specialists: Working project for construction of 220

kV open switchgear at Kazan CHP-3 with two 125 MVA automatic transformers;

Rehabilitation of 220/110/35/6 kV Suleyevo Substation Almetyevsk electrical networks, Studenets Bugulma electrical networks;

Rehabilitation of open switchgears, closed switchgears at Kazan CHP-3, Nizh-nekamsk CHP, Urussu SDPP, Zainsk SDPP, Kazan Electric Networks, Yelabuga Electric Nretworks, etc. including replacement of electric equipment. Protection of modern equipment was performed with the use of microprocessor technology as replacement of electromechanical devices;

Working project of 110/6 kV Sidorovka Substation;

Naberezhnye Chelny Electrical Networks; Working project of Pismyanka Substation-15;

Rehabilitation of 110 kV open switch-gear (5 cells), 6 kV closed switchgear; Bu-gulma electrical networks;

Rehabilitation of 220 kV Nizhnekams-kaya Substation, 110 kV open switchgear; Nizhnekamsk electrical networks;

220/110/35/6 kV Abdrakhmanovo Substa-tion. 110 kV open switchgear (2nd stage). 2nd stage of design; Almetyevsk Electrical Networks;

Rehabilitation of35 kV Severnaya Substa-tion including transition to 110 kV; Kazan CHP-2.

Introduction of advanced management modes of equipment, frequency regulation of pumps

Projects with participation of our specialists: Installation project for Voith Turbo hy-

draulically actuated clutch on feedwater pumps at Zainsk SDPP, Naberezhnye Chelny CHP, Nizhnekamsk CHP, network pumps at the industrial boiler house-1, 3 at Naberezh-nye Chelny CHP;

Introduction of RU-DRIVE high-voltage frequency converters at the booster pump-ing plant-5 of Naberezhnye Chelny Heat Distribution Company (2 pcs.), on KSNR-3 network pumps, on drill pumps (13 pcs.), Tat-neft-Burenie OJSC;

Introduction project of Vacon frequen-cy converter on network pumps at Nizh-nekamsk CHP-1, Kazan CHP-3, pump station Nos.2, 5 of Nizhnekamsk operational area (Kazan Heating Networks).

Innovation energy on the moveInnovation energy on the move

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FIELD OF ACTIVITIES

Automation services:

Designing. Supply of equipment. Installation and commissioning. Technical and service maintenance, repair.

DCS for heat and hydraulic power industry: DCS of main equipment at TPP (power units,

boiler units, turbine generating units) and HPP (hy-droelectric sets);

DCS of auxiliary equipment at TPP (chemical water treatment, feedwater installations, techni-cal water supply, etc.);

DCS of fuel handling facilities at TPP (fuel oil handling facilities, gas distribution plants, fuel handling);

DCS of small-scale systems and heat supply (steam and hot-water boilers, boiler houses).

DCS for electric power industry: Automated Control Systems for electric

equipment of stations and substations (remote control, Automatic system for Commercial Me-tering of Electric Energy, monitoring of relay pro-tection, automation and emergency automation devices, monitoring of power equipment);

Automation of control centres of all levels (a substation, the distribution zone, Electric Net-work Enterprise, Energosystems Grid Control Centre).

DCS for housing and public utilities: DCS for booster pumping stations; DCS for sewage pumping stations; DCS for treatment facilities; DCS for pump stations of heat distribution

(district heat stations, booster pumping stations, central heating units, etc.);

Automated Systems for Commercial and Technical Metering (Automatic Systems for Com-mercial Metering of Electric Energy, Automatic Systems for Commercial Metering of Heat, Auto-matic Systems for Commercial Metering of Gas).

DCS for machine building and automotive industry:

CNC systems; Test stands of equipment; DCS of crane fa-

cilities; DCS for pressure machines;

DCS for conveyer systems.

DCS for various industries: Operative-information packages (MESsys-

tems, SCADA, operative-information packages); Automated Systems for Commercial and

Technical Metering (Automatic Systems for Com-mercial Metering of Electric Energy, Automatic Systems for Commercial Metering of Heat, Auto-matic Systems for Commercial Metering of Gas).

Communications systems ( ber optic lines, Ethernet, radio-Ethernet, radio modem com-munication, dedicated and dial-up lines, high-frequency communication);

Variable frequency electric drive (high fre-quency converters, low-voltage frequency con-verters, DC converters, electric motors, genera-tors);

Microprocessor relay protection; Facility re-mote control systems: re alarm systems, CCTV and others;

Metrological calibration of ow meters and heat meters.

DCS for oil production: Control system for booster pump stations; Group metering pump station control sys-

tem; Group pumping station control system; Balanced pumping unit control system; Drilling rig control system; Automation of oil depots and storage tanks.


STANDARD SOLUTIONS

DCS for power units full-scale control of power units operating on fuel oil and coal to en-sure speci ed given heat and electric power ca-pacity.

The system provides: increasing reliability; improvement of technical and economic

indicators; increasing service life; improvement of working conditions of op-

erating personnel; decreasing operating costs by reducing the

costs of current and scheduled repairs.The hardware and software package is imple-

mented on the base of Ovation (Emerson).Introduced at: Ekibastuz SDPP-1 (Kazakhstan), 6 power

units per 500 MW (st. No.3, 4, 5, 6, 7, 8); Aksu TPP (Kazakhstan), 300 MW power unit st. No.1;

Chelyabinsk CHP-3, 200 MW power unit st. No.1.

Automatic frequency and power regulation system for power units is designed to ensure power unit participation in frequency control (rat-ed primary and automatic secondary) and power control at block-type thermal power plants.

The system also provides: remote centralized unit load control, coor-

dinated automatic regulation of the boiler and turbine;

high level of unit control automation in all modes;

high accuracy of the speci ed load main-tenance.

The hardware and software package is imple-mented on the base of Ovation (Emerson).

Introduced at: Zainsk SDPP, 10 power units per 200 MW (st. No.2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12).

Vibration and mechanical value control sys-tem

The system allows: Perform quality control of energy supplied

or dispensed; Improve reliability and effi ciency of data col-

lection; Signi cantly reduce the cost of mainte-

nance and repair of equipment by improving reli-ability of operation, reducing operating costs for maintenance of switching channels, reducing the number of attendants, i.e. ensure resource sav-ing;

Reduce the time of process failure detec-tion, as well as prevent development of critical faults;

Analyze energy losses of dispensed energy resources, identify areas with high losses;

Develop an effi cient mode of system opera-tion based on accumulated data.

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STANDARD SOLUTIONS

DCS for the gas turbine plant control of gas turbine plant elements: a gas turbine engine, a boiler-utilizer, a booster gas com-pressor and the electrical part of the gas turbine plant.

The system provides: automatic startup of the plant includ-

ing connection to the consumers network; improvement management quality;

reliability, increasing service life; improvement of technical and eco-

nomic indicators. The hardware and software package

is implemented on the base of Ovation (Emerson).

Introduced at: Kazan CHP-1, two gas turbine plants

per 25 MW; Lida CHP (Belarus), 25 MW gas turbine

plant; TKN-VR, two gas turbine plants per 5

MW.

Automatic vibration and diagnostic monitoring system (ASKVD) of the turbine generating unit is designed for continu-ous monitoring of vibration, process status of the turbine generating unit in stationary and transient operational modes.

The system provides: reducing probability of false shutdowns of

units associated with malfunction of measur-ing systems, prevents accidents, emergency or forced shutdowns as well as sudden de-struction of the turbine generating unit.

Introduced at: Nizhnekamsk CHP; Kazan CHP-2; Kazan CHP-3; Naberezhnye Chelny CHP; Zainsk SDPP; Urussu SDPP.

DCS for the hydraulic unit provides reliable, economic and safe operation of hydraulic units.

The system provides:In relation to main process equipment: improvement of operational quality of

hydraulic units (ensuring process modes of operation, increasing plant availability fac-tor, etc.)

reducing operational costs.Introduced at: Nizhnekamsk HPP, hydraulic units

Nos.9, 10, 11, 12.


Turbo feed pump control system.Designation and functions:An object of control is a steam turbine and

a feed pump together forming a single unit a turbo feed pump.

The automatic control, regulation and pro-tection system for the turbo feed pump allows operational control of the feed pump by chang-ing its speed.

This system provides management and participates in control of the turbo feed pump in the following operating modes:

veri cation of prestart readiness; startup of the turbo feed pump; rise of the turbo feed pump to operating

pumps; connecting of the turbo feed pump to the

network (of the feed pipeline); normal operating conditions; placement of

the turbo feed pump under idling conditions at disconnection of the turbo feed pump

from the feed pipeline network (recirculation mode);

shutdown mode (both normal and emer-gency).

The automatic control, control and protec-tion system for the turbo feed pump performs the following tasks which can be divided into groups:

regulation of the turbo feed pump; emergency protection; actuator control; information functions, operator interface.

Introduced at:Novo-Kemerovo CHP (Kuzbassenergo OJSC)

STANDARD SOLUTIONS

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STANDARD SOLUTIONS

DCS for the boiler unit increasing ef- ciency, reliability and safety of the boiler unit under all operating conditions. DCS is performed as a single system for the whole boiler unit and its auxiliary equipment.

The system provides: reliable, effi cient and safe operation of

the boiler unit; improvement of operational quality of

th boiler unit (ensuring process modes of operation, increasing plant availability fac-tor, etc.)

reducing operational costs.The hardware and software package is

implemented on the base of PCS (Siemens), Ovation (Emerson), Krug-2000 (Krug).

Introduced at: Kazan CHP-1, the boiler unit st. No.11; Kazan CHP-2, the boiler units st. Nos.7,

11; Kazan CHP-3, the boiler unit st. No.5; CHP-1, Aktau (Kazakhstan), the boiler

units st. No. 4, 5; CHP-2, . (Kazakhstan), the boiler

units st. No.1, 10, 11, 12, 13; Lida CHP (Belarus), the boiler unit No.2;

DCS for the boiler unit ignition designed for process control of burner ignition in boiler units of diff erent capacities working on fuels such as gas and conform with the Safety rules for gas distribution and consumption of the gas supply system.

The system provides: ignition by introducing modern manage-

ment system based on the industrial hardware and software package that meets all equire-ments for functionality, security and fault toler-ance of automated systems;

Increasing survivability due to the use of the redundancy and backup principle for main units and systems precluding a system failure in case of failure of any element or loss of sup-ply voltage.

Introduced at: Smolensk SDPP, the boiler units st. No.2, 3; Verkhny Tagil SDPP, the boiler unit st.

No.16; Zainsk SDPP, the boiler unit st. No.6.


STANDARD SOLUTIONS

DCS for water treatment installations au-tomatic and manual control of chemical water treatment processes.

The system provides: automatic regulation of process parameters in

controlled processes under the speci ed settings; automatic functional group control; manual (local) control of equipment from local

control rooms; manual (remote) control of equipment from

panels of control cabinet operators and a control center;

process interlocks, protections and alarms; visualization and process control using opera-

tors automated workplace (AWP) in the control room; alarm (visual and sound) system of equipment

fault conditions and overanging of process param-eters.

The hardware and software package is designed on the base of Siemens equipment and software.

Introduced at: Kazan CHP-1; Kazan CHP-2; Kazan CHP-3; Nizhnekamsk CHP; Zainsk SDPP; Tomsk CHP-3.

DCS for the gas distribution plant automatic, remote and local manual control of the gas distri-bution plant.

The system provides: high reliability of gas supply to consumers;

high level of process security; environmental safety of manufacture; high quality of the process management

due to modern regulation algorithms; effi ciency of gas distribution plant manage-

ment, coordinated management of supply fa-cilities and gas reducing from the uni ed control point;

increasing reliability and maintainability of control equipment;

developed diagnostic tools to reduce the time for repairs;

statistical accumulation of equipment oper-ation data to predict preventative maintenance.

Implemented on the base of Siemens.

Introduced at: Nizhnekamsk CHP; Zainsk SDPP; Kazan CHP-3.

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STANDARD SOLUTIONS

DCS for the pump station control and management of process operational modes of pumps at the pump station, as well as its auxiliary mechanisms.

DCS for the pump station is used in water supply systems, re ghting systems, boiler feed and water transport, control systems for CHP, boiler rooms and central heat sup-ply stations.

The system provides: signi cant reduction of power con-

sumption at pump stations and increase of process effi ciency;

reducing operational costs and pro-cess losses: decrease of inter-repair cycle of pump and electric equipment, pipeline valves, increase of their service life, reducing risk of pipeline ruptures;

technology quality improvement due the use of developed tools of browsing and analysis of accumulated process informa-tion;

developed diagnostic tools to reduce the time for repairs;

statistical accumulation of equipment operation data to predict preventative main-tenance.

The hardware and software package is implemented on the base of Siemens.

Introduced at: Zainsk SDPP; Kazan CHP-1; Kazan CHP-2; Naberezhnye Chelny CHP; Nizhnekamsk CHP; Housing and Public Utilities (Kazan, Naberezhnye Chelny.

The commercial metering system of thermal energy, liquid and gas ow data acquisition from metering stations of heat-ing energy, liquid and gas ow in the uni- ed control point. Commercial metering of liquids (including sewage water) and gas is carried out.

The system allows: Perform quality control of energy sup-

plied or dispensed; Improve reliability and effi ciency of data

collection; Signi cantly reduce the cost of mainte-

nance and repair of equipment by improving reliability of operation, reducing operating costs for maintenance of switching chan-nels, reducing the number of attendants, i.e. ensure resource saving;

Reduce the time of process failure de-tection, as well as prevent development of critical faults;

Analyze energy losses of dispensed energy resources, identify areas with high losses;

Develop an effi cient mode of system operation based on accumulated data.

Introduced at: Zainsk SDPP; Kazan CHP-1; Naberezhnye Chelny CHP; 630 apartment buildings (Naberezhnye

Chelny); District boiler houses Azino, Savinovo

(Kazan).


STANDARD SOLUTIONS

Control system for booster pump stationsProcess management and control at booster

pump stations including: at intermediate oil con-tainers, oil delivery pumping units, multiphase installations, line heaters, gas separators, gas tanks, intermediate water tanks, intermediate water tanks, oil basic production ow meters, sampler devices and gas analyzers.

Main functions: liquid level measurement in tanks, automatic regulation of liquid level; automation system management; data

transfer to control centers; security alarm system management at the

booster pumping station rooms; re alarm system management at the

booster pumping station; temperature measure-ment in the Control and Instrumentation room, etc.

Introduced at: Tatneft OJSC.

Control system for group meteringpump stations

Process management and control at group metering pump stations including: at interme-diate oil containers, oil delivery pumping units, drainage tanks, oil and water basic production ow meters.

Main functions: liquid level measurement in tanks; level alarm in each of tanks (top emergency

level, upper level, lower level); automatic regula-tion of oil level within the speci ed limits; voltage availability control;

monitoring of security alarm for the group-metering pump station rooms;

Monitoring of re alarm for the group-me-tering pump station, etc.

Control system for cluster pump stationsProcess management and control of cluster

pump stations.Main functions: Startup and shutdown control of the main

pump which raises water pressure in the manual and automatic mode;

Emergency and process parameter con-trol within the speci ed limits and, if necessary, emergency shutdown;

Communication with the dispatching sys-tem for telemetry and remote control, etc.

Introduced at: Tatneft OJSC.

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STANDARD SOLUTIONS

DCS for power supply (remote con-trol, relay protection and automatics and emergency control schemes monitoring, DCS, Automated Dispatch Control Sys-tems) operational dispatching manage-ment and data exchange with the auto-mated system with the system operator.

The system provides: high reliability of facility operation; operational dispatching manage-

ment; process data exchange with the au-

tomated system with the system opera-tor;

high reliability of the substation by monitoring the internal state of the facility (definition of equipment performance ca-pability, management of equipment criti-cal parameters, fire alarm, security alarm systems);

parameter accuracy.Introduced at: Zainsk SDPP; Nizhnekamsk HPP; Naberezhnye Chelny CHP; Urussu SDPP; Kazan CHP 1, 2, 3; Kazan electrical networks; Bugulma electrical networks; TANEKO OJSC.

DCS for substation electric equip-ment substation process control. Facil-ity control from the unified control center is performed due to subsystem incorpora-

tion: relay protection and automatics and emergency control schemes monitoring, Automated Dispatch Control Systems, Au-tomated Measuring and Information Sys-tem for Commercial Metering of Electric Energy, Automated Measuring and Infor-mation System for Commercial Metering of Thermal Energy, diagnostic system of the main equipment.

The system provides: high reliability of the substation oper-

ation due to operational interaction with related objects (remote control and relay protection status);

high reliability of the substation by continuous monitoring of the facility (definition of equipment performance ca-pability, management of equipment criti-cal parameters, fire alarm, security alarm systems);

increase of reliability and maintain-ability of control equipment, reducing of operational costs and process losses: increase of inter-repair cycle of electric equipment, increase of service life, etc.;

Introduced at: Kazan electrical networks; Bugulma electrical networks; Volga electrical networks; Nizhnekamsk electrical networks.


STANDARD SOLUTIONS

Control system for drilling pump in a container design

Designation: frequency regulation of pump unit perfor-

mance; control of auxiliary electrical machinery and

mechanisms of the pump module.Main functions: automatic startup and shutdown of mod-

ule equipment by means of corresponding algo-rithms;

trip of the module in emergency events and generation of the corresponding message to the operators panel;

delivery of control actions on the frequency converter of the drill pump drive;

archiving of the module parameters and re-port generation;

maintenance of temperature mode (+15..+35 ) in the module (at the ambient tem-perature from 40 to +40 ).

The system is based on RU-DRIVE medium-voltage frequency converter located in the con-tainer.

The hardware package includes: A medium-voltage frequency converter (6

kV); A central cabinet of the pump plant auto-

matic control; A single-block precision air conditioner; An incoming cubicle; An insulated container with a rigid welded

frame of steel beams and pro les.

A Mobile Control Cabinet for the pumping jackA Mobile Control Cabinet for the pumping jack

based on the variable frequency drive is designed for optimum control of the sucker rod pump elec-tric motor.

A Mobile Cabinet is applied at oil producing companies that use sucker rod pump plants with pumping jacks for oil production.

Main functions: smooth bumpless startup of the pumping

unit drive motor with programmable acceleration time;

smooth bumpless automatic startup with programmable startup delay time after power failure;

continuously variable number of oscillations of the pumping jack in the automatic and manual mode from 0 to 200% of the rated oscillations;

automatic self-tuning of pumping mode en-suring maximum ll of the plunger pump;

speed regulation of the rod string move-ment from cycle to cycle and within the cycle ac-cording to any given law, etc.

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Integrated systems of bridge technical securityBuilding of the integrated system allows to

maintain the highest level of security.

The package includes: a video surveillance system; a security

and alarm system; a perimeter security lighting alarm sys-

tem; an automatic re alarm and re extin-

guishing system; an information, warning and evacuation

system; an automated control system for road

safety; an access monitoring and control system; an emergency calling and dispatch com-

munication system; a local area network system, a bre optic

communication line; a power supply system.

Introduced at: A bridge crossing over the Volga river, Vol-

gograd city;A bridge crossing over the Vyatka river,

Mamadysh city;

A perimeter security alarm and CCTV systemThe system is designed for: registering attempts of trespassing of the

protected area and generating relevant infor-mation about such trespassing to the offi cials

who perform operational duty in the facility for decision-making;

a patrolling mode in the video surveil-lance system for an alarm line of the protected facility;

Main functions: video surveillance of an alarm line; display of TV images from all cameras at

the central guard post; recording of TV images when receiving

alarm messages; viewing of the video data base; coopera-

tion with previously installed systems.Introduced at: Zainsk SDPP; Nizhnekamsk CHP; Yelabuga CHP.

STANDARD SOLUTIONS


LEADING PROJECTSIN THE FIELD OF INDUSTRIAL AUTOMATION

POWER SECTOR

DCS for 220 MW CCGT at Kazan CHP-2The project is implemented within the frame-

work of 220 MW CCGT construction at Kazan CHP-2. Construction period: 2011 - 2014.

Management Company KER-Holding LLC is the General Contractor (EPC-contractor).

KER-Engineering Company is the General De-signer, it is also responsible for turnkey DCS imple-mentation and a full range of services regarding electric equipment. The Vendor of the software and hardware package for DCS was competi-tively selected together with the Customer and the General Contractor. Congifuration of the soft-ware and hardware package was determined. Contracts were signed with GE Company for the software and hardware package supply and engi-neering support of the Project. Designers of KER-Engineering were trained to use 6000 System in GE Center of Automation System Development and Production (Shanghai, China).

DCS for a new power unit at Abakan CHPThe Contract was signed with SiberiaEnergo-

Engineering OJSC for turnkey creation of DCS for a new power unit st. No.5 at Abakan CHP (Yenisey Territorial Generating Company-13 OJSC.)

A branch of KER-Engineering, KER-Avtomati-ka Company acts as a contractor to design DCS upper level, installation of eld instrumentation and commissioning. The Vendor of the hardware and software package for a new power unit is Metso Corporation, a contract was signed for

supply from Metso Automation CJSC.The automation system for the power unit is

designed to optimize processes, ensure high reli-ability and reduce human factor in uence.

Upgrading of Automatic Frequency and Active Power Regulation Systems for 11 power units per

200 MW each at Zainsk SDPPThe Automatic Frequency and Power Regu-

lation System is designed to ensure power unit participation in frequency and power control at block-type thermal power plants. According to the results of the work performed, certi cates of conformity with the standard of the System Op-erator Central Dispatch Department of Russian Uni ed Energy Systems OJSC. Result: active par-ticipation of power units at the ancillary service market since 2011.

Upgrading of control and management systems for 6 power units per 500 MW each at Ekibastuz

SDPP-1 (Kazakhstan) including introduction of the full-scale DCS

A modern DCS is designed for process control of high capacity fuel oil- or coal-powered power units. A modern DCS for a power unit is imple-mented based on Ovation hardware and soft-ware package.

Result: full-scale automatic control of the power unit with the purpose to provide speci ed heat and electric power.

DCS of 50 MW gas turbine unit at Kazan CHP-1 DCS is designed for control of all gas turbine

plant elements: a gas turbine engine, a boiler-uti-lizer, a booster gas compressor and the electrical part of the gas turbine plant.

The gas turbine plant is equipped with the control and management system based on Ova-tion hardware and software package (Emerson).

Result: automatic regulation of process pa-rameters with speci ed characteristics, control

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of the fuel rate controller in the gas turbine engine; functional group control (startup of the gas turbine engine including its connec-tion to the network).

Upgrading of control and management of boilers and turbines at Kazan CHP-1, Kazan

CHP-2, Kazan CHP-3, Ust-Kamenogorsk CHP, CHP-1, Aktau CHP-2, Petropavlovsk

CHPThe full-scale DCS provides process con-

trol of boilers and turbines of various capac-ity.

All implemented DCS are built on the base of modern hardware and software packages: Ovation (Emerson), PCS 7 (Sie-mens), KRUG-2000 (Scienti c and Production Company KRUG),

Result: full-scale automatic control of the boiler and turbine with the purpose to pro-vide speci ed heat and electric power.

Introduction of automatic ignition systems for boiler units at Smolensk SDPP, Verkhniy

Tagil SDPP and Zainsk SDPPAn automatic ignition system is designed

to improve industrial safety and reliability of the boiler unit. All implemented automatic ignition systems are accomplished using AMAKS gas units based on Ovation (Emer-son) and PCS 7 (Siemens) software and hard-ware packages.

Result: compliance of gas facilities with safety rules of gas consumption systems.

Introduction of information and measuring systems at CHP-2, CHP-3 (Aktau), Na-

berezhnye Chelny CHP, Nizhnekamsk CHPThe systems provide the required accu-

racy, reliability and timeliness of operational information provided to the staff , improve-ment of equipment reliability due to high fault tolerance of modern hardware and

software packages: Ovation (Emerson) and PCS 7 (Siemens).

Result: introduction of the information and measuring system which besides solv-ing monitoring tasks allows to create a base for the follow-up expansion of the system and increase the number of functions (for example, implementation of the automated control system for the boiler unit No.1 CHP-2 (Aktau) on the base of the implemented in-formation and measuring system).

OIL AND GAS INDUSTRY

Design of the Automated System for Elec-tric Energy Accounting at TANEKO Re nery

and Petrochemical Plant ComplexThe power supply system of the Com-

plex includes: steam supply, power supply, and Automated System for Electric Energy Accounting. The project includes innovative solutions by KER-Avtomatika and Siemens.

Result: an optimal energy supply sys-tem is developed with due regard to phased construction of internal and external power supply facilities.

HOUSING AND PUBLIC UTILITY SECTOR

Analysis of equipment operation at over 800 central thermal points in Moscow

(MOEK OJSC)Analysis of operational modes and pa-

rameters of the equipment at central ther-mal points was carried out. Result: off ers for


design of automatic regulation systems with use of frequency drives were developed.

Development and introduction of the dispatch-ing system for heat and hot water metering stations in 630 apartment buildings in Na-

berezhnye ChelnyInnovative solutions in the eld of commercial

metering of heat energy, water, gas has been im-plemented. For this development, the Company was awarded with the diploma of the Ministry of Industry and Trade of the Republic of Tatarstan in the competition of energy effi cient equipment and technologies.

Result: introduction of energy- and resource-saving technologies in housing and public utili-ties, rational mode of heat consumption.

MACHINE-BUILDING INDUSTRY

Development and introduction of internal com-bustion engine test stands in KAMAZ OJSCKontur-Sid software and hardware package

developed by KER-Avtomatika specialists is in-tended for automatic control of test stand and automatic line equipment. Kontur-Sid package is based on a variable frequency drive with a recov-ery function (energy return for reuse in the same process). Result: increase of accuracy and reli-ability of control systems due to introduction of new and high technology equipment; improving of technical and economic indicators.

Upgrading of the main assembly line at the automobile plant (KAMAZ OJSC)

The control system and electric part have been replaced. The following modern Siemens equipment has been installed: Simatic S7-300

controller, frequency converters, etc. Supervisory control has been performed. The synchronizing system for automobile and footway conveyors has concurrently been restored. Result: improve-ment of conveyor reliability, increase in labor pro-ductivity.

CITY AND TRANSPORT INFRASTRUCTURE

Construction of the integrated security support system of bridge crossings over the Volga river

(Volgograd) and the Vyatka river (Mamadysh)The multipurpose platform integrates dispa-

rate systems in a coordinated working infrastruc-ture. The platform includes the following subsys-tems: the video surveillance system, the alarm system, the warning and evacuation system, the road safety system, the re alarm and re extin-guishing system, the power supply system, local area networks.

Result: reliable control, security service opti-mization, reducing costs.

PULP AND PAPER INDUSTRY

Upgrading of gas pipelines and DCS of steam boilers at Employee-owned Enterprise Na-berezhnye Chelny Cardboard and Paper Mill

CJSCAt Naberezhnye Chelny Cardboard and Pa-

per Mill upgrading of steam pipelines and DCS of steam boilers -160-24-250 GM st. Nos.1, 2 and PTVM-ZOM (r) as well as auxiliary equipment has been performed on the base of PCS 7 hardware and software package (Siemens).

Due to introduction, management effi ciency and boiler reliability has been increased, techni-cal and economic indicators have been improved.

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COMPETENCES OF ELECTRICAL DIRECTION

Rehabilitation and construction of 6 220kV substations

Installation of metalware; Installation of power equipment (mains

transformers and measuring transformers; vacuum and SF6 circuit breakers, etc.);

Installation of secondary circuits: con-trol cables, external, internal and protective lighting;

Installation of power compensation systems;

Installation of relay protection, auto-matics and emergency control schemes, carrier-current protection and HF commu-nication;

Installation of Automated Process Con-trol Systems for electrical energy supply, communication systems (including ber-optic lines), re and security alarm and CCTV monitoring systems;

High-voltage tests; Commissioning works (power equip-

ment, relay protection and automatics, emergency control schemes);

Commissioning works of automated control and communication systems.

Rehabilitation of electricalequipment at generating stations

Power equipment: generator circuit breakers and disconnectors, current and voltage transformers, conductors;

Generator relay protection and auto-matics, emergency control schemes;

Electrical part of auxiliary mechanisms in turbo-and hydro generating units, 0.4 - 6 kV switchgears;

Automated Process Control Subsys-tems of electrical equipment;

Excitation systems.

Repair of 0.4 220kV class power electrical equipment

Measuring current and voltage trans-formers;

Power cable lines and cable installa-tions;

Cable communication lines; Switchgears, including switching equip-

ment; Accumulator installations and DC

shields; Earthling equipment and overvoltage

protection devices; Lighting installations; Relay protection and automatics and

emergency control schemes; Automated Control Systems of Electri-

cal Energy Supply: remote control, Automat-ed Information and Measuring System for Commercial Metering of Electrical Energy.


LEADING PROJECTS IN THE ELECTRICAL DIRECTION

Construction of Elabuga-500 new genera-tion substation

The substation is designed to meet the growing demand for electricity of enterprises located in Alabuga special economic zone. The substation is designed to provide power for the Complex of petrochemical and re n-ing plants in Nizhnekamsk (TANEKO OJSC). Besides, the substation will increase electric power supply for Elabuga and Kazan. As a re-sult of the bid, KER-Engineering Company is de ned as the General Contractor. The work started in 2011. And already in 2013, the rst electricity was supplied to consumers.

Reconstruction of 500 kV Kinderi substationKinderi Substation is a 500kV master sub-

station, it provides electrical energy to Kazan power district consumers; energy emergency in peak-load hours reaches 700MW. Recon-struction of Kinderi Substation is justi ed by the need to increase electric power supply reliability for the speci ed power district. One of the most powerful transit of electricity in Russia - the Northern transit - is performed through Kinderi Substation. Staged and scale reconstruction of Kinderi substation has been carried out since 2000. Since 2011, a new stage of integrated reconstruction for Kin-deri substation has begun with the purpose to provide Kazan consumers and facilities of Universiade 2013 with reliable electric power supply.

Upgrading of the excitation system at Zainsk SDPP

Upgrading of TVG-200-2 turbine generat-ing unit st. No.12 has been performed includ-ing replacement of the outdated system for a modern thyristor self-excitation system at Power Machines OJSC. KER-Avtomatika Company has performed thewhole range of services from design to construction, instal-lation and commissioning works.

Rehabilitation of main electric equipment in Mosenergo OJSC

KER-Avtomatika took an active part in re-habilitation of electric equipment at CHP-17 and CHP-23 (Moscow). Particularly, rehabilita-tion of the power unit st. No.4 was performed at CHP-17: the worn-out and obsolete -1002 turbine generating unit with the electric machine excitation system was replaced with a modern TZFP-1102 MUZ turbine generat-ing unit with a capacity of 110 MW completed with the static thyristor excitation system.

Rehabilitation of 35220 kV circuit breakers at Bugulma-500 Substation

Replacement of 220 kV air circuit break-ers for SF6 circuit breakers was carried out in 2009 at Bugulma-500 Substation (Bugulma Electrical Networks). Rehabilitation of two cells 220 kV Bugulma-Pismyanka overhead transmission line and 220 kV Bugulma- Ab-drakhmanovo overhead transmission line.

Construction, installation and commis-sioning work was performed together with Electroneftegas LLC. This included disman-tling of appr. 2 km of cable and cabling of a 9 km new line, a full range of adjustment work was performed with regard to relay pro-tection and automatics. Satisfactory labour management at the substation and timely delivery of materials and equipment made it possible to implement the rehabilitation work during one month.

Besides replacement work of 220 kV air

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circuit breakers, major repairs of three cells at 220 kV open switchgear was made. It included major repairs of VVB-220 air circuit breakers and RNDZ-220 disconnectors, as well as two 35 kV cells of the open switchgear.

Upgrading of the excitation system at Nizhnekamsktechuglerod OJSC

The existing system of TG-1, 2 tur-bine generating units, type SHSV-3 did not provide parallel operation of said tur-bine generating units in violation of the stability of the power system. A UNITROL 1000 type reliable brushless, diode, digital excitation system by ABB (Switzerland) was installed to eliminate this signi cant drawback.

Rehabilitation of the key single line diagram at Kazan CHP-2 (Generating

Company OJSC)Rehabilitation the key single line dia-

gram at Kazan CHP-2 was performed to provide uninterrupted and reliable power supply for Kazan consumers. Particularly, the following was performed: rehabilita-tion of the open switchgear-35 including replacement of 35 kV cells for 110 kV cells and installation of VEB-110200050 SF6 circuit breakers; rehabilitation of two 35 kV overhead transmission lines at Lenin-skaya Substation to 110 kV cross-linked PE overhead transmission line; rehabilita-tion of DZSH-110 including installation of new panels.

The current-limiting device at Naberezh-nye Chelny CHP (R&D)

TOU-N-110 current-limiting devices were installed at Naberezhnye Chelny CHP in neutrals of -3, -4, -6, -7 block transformers and AT-5, AT-8 single wind-ing transformers for limitation of inter-ruptible steady short-circuit currents and surge currents of transformers.

As compared to traditional methods of current-limiting divisions, current-lim-iting networks have such advantages as: action inertialess, 1.5-2.5 time limitation of short-circuit surge currents, 1.2-1.4 time limitation of hazardous short-cir-cuit let-through currents in transformer windings.

Use of current-limiting devices con-tributes to maintaining dynamic stabil-ity of power systems during emergency disturbance related to switching of acci-dental and arti cial short circuits. Use of current-limiting devices allows to reduce turbine unloading necessary to preserve the 20-40% stability and also improve intersystem connection capacity up to 25%.

Upgrading of VVG-20 generator circuit breakers including replacement of relay

protection and automatics at Nizh-nekamsk HPP

At Nizhnekamsk HPP, the electric scheme of 4 unitized blocks is used in-cluding connection of two pairs of hy-draulic generators to the block-type transformer through VVG-20 type air circuit breaker. Due to obsolescence and physical deterioration of the speci ed circuit breakers being used in heavy con-ditions (the number of operating cycles per year is more than 500), replacement of VVG-20 type circuit breakers to SF6 type is provided in the investment pro-gram of Generating Company OJSC.

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According to the level of switchable short-circuit currents on generator voltage busbars (short circuit reference point 1), a SF6 circuit breaker with breaking currents more than 150 kA shall be applied. The only one circuit breaker that suits such breaking currents is HEC-7 type circuit breaker by ABB Company (Switzerland) with breaking current of 160 kA. However, the cost of HEC-7 is appr. $1 mln. And its overall dimensions do not allow to install it into the existing camera of VVG-20 circuit breaker.

For this reason, it has been determined to use a SF6 circuit breaker of the same manu-facturer, HECS-130R type instead HEC-7 of for replacement of VVG-20 circuit breaker, as its cost is 3.5 times less than the cost of HEC-7. But the rated short circuit breaking current makes up all in all 130 kA, i.e. less than the calculated breaking current which is 146.2 kA.

To provide compliance with interrupting capacity of short circuit currents in the gen-erator, it has been determined to apply step cutoff : cut off the circuit breaker of an adja-cent pair of generators with the rst time de-lay, and then cut off the circuit breaker of the damaged pairs.

At such cutoff , current decreases to 112.8 kA, i.e. complies with interrupting capability of HECS-130R.

In 2008 the rst project was implement-ed regarding replacement of two generator circuit-breakers including simultaneous re-placement of protection to microprocessor type.

Upgrading of 6 kV integrated switchgearat Naberezhnye chelny CHP

Upgrading of 6 kV integrated switchgear, section 2 , and 4 , includes:

replacement of worn-out and obsolete VMPE-10 oil circuit breakers to VBE-1031,5/630 (1000, 1600) UHL-2 vacuum circuit breakers;

replacement of relay protection and control equipment based on electromechan-ical relays to SPAC 810 type microprocessor equipment which provides high accuracy and consistency of performance. This can signi -cantly improve reliability, sensitivity and high-speed performance of protection, as well as reduce selectivity level.

Surge arresters OPN-6 were installed to protect transformers, electric motors and 6 kV busbars from surge voltage.

The arc protection unit complete with Duga-0 arc fault registration unit was assem-bled to protect equipment from short circuits; replacement of NTMI6 voltage transformer to ferroresonance transformers NAMIT-10-2 UHL was made.

Upgrading of 0.4 kV BOP switchgearat Naberezhnye Chelny CHP

Upgrading of 0.4 kV BOP switchgear (1 nor-mally open contact) provides replacement of obsolete overaged equipment that requires costly spare parts (discontinued) for modern equipment satisfying all requirements and standards.

During the project implementation, pan-els of Neva control board low-voltage unit (produced by Eltehnika-Volga) were mounted complete with Schneider Electric Masterpact NT16 and Compact NSX1OO-630 A type cir-cuit breakers. To reduce mechanical stress on electric motors and improve their operational availability, Altistart 48 soft starters ensuring high reliability, security and ease of com-missioning were mounted. Replacement of power and control cables, secondary circuit wiring and relay protection devices was also performed.

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board at Naberezhnye Chelny CHPNormal operation of DC Board equip-

ment in uences electric equipment maintainability at electric plants and net-works.

At large power plants and substations, DC centralized battery supply leads to the need for construction of control current extended and extensive network.

DC Board is designed to provide di-rect current supply to consumers. The Board structurally consists of 9 closed double operation cabinets with bottom feed-through and 7 distribution panels. DC board cabinets are manufactured in Convertor CJSC (Moscow).

A distribution part of DC board consists of three sections combined with section-al switches. Working supply input is made to the second section, from that section nominal reserve supply of the DC Board is performed through the interredundancy panel. Emergency oil pump motors, sole-noid supply circuits, emergency lighting, alarm and control circuits are powered by the rst and third sections. Protection of DC Board connections is performed with automated VA 5541 type circuit break-ers and RBKOO power cutout switches (with PPN-33 fuse elements -33).

The microprocessor automation sys-tem is used for monitoring the status of direct current in the DC Board.

Dispatch boards of Grid Company OJSCThe Dispatch Service of Grid Company

OJSC is designed to ensure: fault toler-ance and reliability of the power system, distribution of electric energy in accord-ance with the schedule load, support for installed power system parameters (volt-age, frequency in the power supply cir-cuit, etc.), maximum operation effi ciency of the power system as a result of opti-mal use of various energy sources. Any changes in operational modes and status of the power system elements are to be

displayed in a convenient form for the dispatcher.

For today, dispatch boards are the most common devices for display of large-scale circuits in the integral form. The dispatcher uses them to manage and coordinate joint operation of several electrical circuits within a single grid.

Status information of grid facilities and subsystems included into it is col-lected, processed and displayed by auto-mated systems.

This task is successfully solved by modern control and monitoring systems by KER-Engineering included into DATS hardware and software package: DATS AKP, DATS APU, DATS ADSHCH.

Having a multi-module structure, DATS hardware and software package provides high fault tolerance and scalability for fu-ture upgrading. Multifunctionality of DATS hardware and software package allows to perform collection, processing, stor-age and transfer of information, along with providing time synchronization with low level devices.

Introduction of the emergency parame-ter recording system for relay protection

and emergency automatics Grid Com-pany OJSC, Generating Company OJSC

According to the requirements of the system operator, when an alarm event occurs, emergency oscillograms shall be provided to a representative of the sys-tem operator within 30 minutes.


Protection packages by diff erent manu-facturers and remoteness of control facilities signi cantly complicate this task. In 2008-2009, projects have been developed monitor-ing systems for relay protection and emer-gency automation have been implemented at all stations of Generating Company OJSC and 4 substations of Grid Company OJSC (Ta-tenergo). In this regard, optimum selection of equipment for each facility without any strict peg to a certain manufacturer was provided (in our projects we used equipment by Ecra Scienti c and Production Company, Prosoft-Systems Company, ABB, etc.) It is planned to introduce this system at all 110220 kV substations of Grid Company OJSC during 10 years.

Since 2010, it is planned to connect all the newly introduced monitoring systems into the Control Center of Grid Company OJSC.

Upgrading of emergency automatics at Nizh-nekamsk HPP (500 kV lines)

In 2009 implementation of emergency automatics upgrading project (2nd startup package).

Taking into account increasing importance of this project in uninterrupted and reliable electric supply to consumers in Kama region industrial area, we involved leading adjust-ment companies in Russia for individual ad-justment works (in the eld of relay protection and emergency automatics) - KaskadGroup Company, Ecra Scienti c and Production Company, Prosoft-Systems Company.

2 high-voltage receivers and transmitters were installed, adjusted and commissioned at 500 kV overhead transmission line Udmurts-kaya and 500 kV overhead transmission line Zianskaya (per each speci ed line).

The work under the speci ed project was continued in 2010. The ultimate goal is au-tomatic loading and unloading of hydraulic generators at Nizhnekamsk HPP, and, if nec-essary, energizing of reserve hydroelectric generators and de-energizing of operating ones at de cit and surplus power, respective-ly, in the energy system.

ENERGOTECHNOLOGICAL AUDIT

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Energy and Technology AuditEnergy surveys allow to de ne eff ective-

ness of industrial processes, consumption and transfer of heat and power energy as well as develop measures to enhance effi -ciency of power equipment and related pro-cesses.

Energy Audit is inspection (energy audit) of enterprise

energy infrastructure; adjustment of heating networks and heat supply systems;

tests and adjustment of heating net-works for thermal and hydraulic losses;

technical and economic analysis of op-timization options for composition and op-erational modes of main and auxiliary equip-ment, circuits of heat and electric power supply;

calculation and expert examination of loss limits, speci c rates of heat and elec-tric power consumption for production and transport, norms fuel stockpiling standards.

We suggest: technical examination of heat and

steam supply systems, metering stations in-cluding analysis of existing modes using ad-vanced computer modeling techniques (GIS Zulu);

statement of reasons for own genera-tion installations of compressor packages, gas turbine plants at CHP including calcula-tion of optimum schemes for including them into the power supply system;

implementation of methods and soft-ware packages for calculation of electric en-ergy loss standards in electric networks of a company;

introduction analysis of variable fre-quency drives and uid couplings for pump equipment;

electronic schemes of heat supply for a district, a city, an enterprise including optimi-zation of heating system operational mode and generation capacity equipment load.

The Customer gets: reliable information about energy con-

sumption on the inspected facility; solutions for optimization of heat- and

electric supply; eff ectiveness evaluation of energy re-

source use; decrease in heat consumption for bal-

ance of plant, ensuring the required heating mode;

a list of energy-saving measures, up-grade options, technical and economic cal-culations and choice of optimal investment into development of a company infrastruc-ture;

a enterprise energy certi cate.The work is performed on the base of: a Certi cate of inclusion on the register

of companies authorized to carry out energy audits is issued by the Central Offi ce of Fuel and Energy Resource Management in the Re-public of Tatarstan;

a Certi cate of inclusion on the register of companies authorized to carry out energy inspections issued by the International Acad-emy of Energy Science;

a Certi cate of membership in Energy Audit Companies Council of Oil and Gas In-dustry;

a Certi cate of energy auditor accredi-tation in GASPROM OJSC.


Integrated diagnostics of electrical equipmentIntegrated diagnostics of electrical equipment

is performed to identify defects at an early stage and prevent emergency shutdown of electrical equipment, planning of maintenance and up-grading of equipment.

Integrated diagnostics is integrated inspection of turbine generating

units and power transformers; inspection and diagnostics of

high-voltage circuit breakers; earthing devices; electric motors; switching devices; suspended and frame insulation; current and voltage transformers; adjustment of Peterson coils; chromatographic analysis of circuit-breaker oil; cable oil; hydrogen from the generator housing; commissioning and maintenance of chro-

matographic systems. qualitative analysis of stator winding insu-

lation abrasion particles in impurities in oil from drainages;

integrated diagnosis of turbine generators during repair;

determination of electronic environment at 110500 kV substation and its in uence to relay protection and emergency automatics

Thermal imaging diagnostics of energy and process equipment

Heat monitoring of electric and heat equip-ment at power facilities, heating networks, ad-ministrative and industrial buildings and struc-tures is required to detect latent defects arising from the installation, repair and on the process of operation

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