Plan of technical re-equipment standard. Technical re-equipment of the enterprise
APPROVED
By the decision of the Duma
dated 03/25/2004 No. 34-gd
Chairman of the Duma
N.F.Popkov
PROGRAM
TECHNICAL RE-EQUIPMENT
MUE "FOOD FACTORY"
FOR 2004 - 2007
Program Passport
| Program name | MUP technical re-equipment program"Food Plant" for 2004 - 2007 |
| Date of the decision to develop the Program, document number | Decision of the meeting on the issue of the reconstruction of the ammonia refrigeration plant and the construction of block boilers for steam supply of MUE "Food Plant". Minutes of April 16, 2003, approved by the First Deputy Head of the Administration Yunakov V.P. |
| Program Customer | Administration of the city of Sarov |
| Program Developer | Municipal unitary enterprise "Food plant" |
| Goals and objectives of the Program |
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| Implementation timeline Programs | 2004 - 2007 |
| Performers Programs | Administration of the city of Sarov, Municipal Unitary Enterprise "Food Plant" |
| Volumes and sources of financing | The total amount of funding for the Program is approximately 15.3 million rubles. Sources of financing:
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| Expected end results |
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| The system for organizing control over the execution of the Program | Control over the execution of the Program is carried out by:
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Introduction
The program of technical re-equipment of the MUP "Food Plant" for 2004 - 2007 (hereinafter referred to as the Program) was developed in accordance with the decision of the meeting on the issue of the reconstruction of the ammonia refrigeration plant and the construction of block boilers for steam supply (minutes dated 16.04.2003, approved by the first deputy head of the Administration Yunakov V. P.)
The need to develop the Program is due to the requirements of the current legislation of the Russian Federation in the field of industrial safety, as well as the requirements of regulatory and guiding documents of the Gosgortekhnadzor of Russia to ensure the industrial safety of hazardous production facilities.
The implementation of the main program activities is currently impossible without the adoption of support measures from the City Administration.
1. The content of the problem and the rationale for the need to solve it by program methods
The Municipal Unitary Enterprise "Food Plant" is one of the enterprises whose normal functioning and uninterrupted production, in particular, bread and bakery products, has a significant impact on maintaining the stability of the social climate in the city. One of the factors for the stable operation of the enterprise is the uninterrupted supply of cold to the following industries: bakery production (raw materials storage chambers), confectionery production (raw materials and finished products storage chambers), ice cream production (raw materials storage chambers, finished products, technological equipment), kvass production (cooling and storage of the finished product).
Since 1981, a centralized refrigeration system has been operating at the Food Plant, the main part of which is an ammonia refrigeration unit (AHU). Until 1999, the operation of the ACS was regulated by the "Rules for the Design and Safe Operation of Ammonia Refrigeration Units", the operation of the ACS was not a licensed activity, and the ACS equipment was not supervised by the local Gosgortekhnadzor.
In 1998-1999 new " General rules explosion safety for fire and explosion hazardous chemical, petrochemical and oil refining industries” (approved by the Decree of the Gosgortekhnadzor of Russia dated December 22, 1997 No. 52) and “Rules for the Design and Safe Operation of Ammonia Refrigeration Units” (approved by the Decree of the Gosgortekhnadzor of Russia dated June 30, 1998 No. 38).
In accordance with the requirements of the new rules, along with periodic testing of AHU vessels and pipelines, after 20 years of their operation, it is necessary to carry out technical diagnostics using ultrasonic and color flaw detection and acoustic emission method, as well as compressor diagnostics. In the case of positive diagnostic results, a permit for operation is given for a period not exceeding 4 years. It is allowed to diagnose each piece of equipment only twice. After the expiration of a 4-year period from the moment of secondary diagnosis, the equipment is subject to mandatory replacement. Thus, the equipment of the ACS of the food processing plant must be replaced no later than 2007, because the primary diagnosis of most of the equipment was carried out in 1999.
In addition, the ammonia refrigeration plant currently operating at the food processing plant does not meet the requirements of the new "Rules ..." in terms of such serious parameters as safety automation, constant automated monitoring of the concentration of ammonia in the air, and the existing building structures of the ACS building also do not meet the requirements of the new rules.
In the current situation, the question naturally arose of reconstructing the ACS of the food processing plant in order to bring it in line with the requirements of new normative documents.
By order of the UKS City Administration in 2000 - 2001. a specialized organization CJSC "Tehagropromservis" (Moscow) developed a project for the reconstruction of the AHU. The estimated cost of the work as of the beginning of 2001 was about 13 million rubles. It should be noted that this project did not provide for the replacement of the technological equipment of the ice cream shop, which has been operated without renovation since the 50s of the last century.
Permanent supervision over the operating conditions of the food processing plant is carried out by RGTI-16. Paragraph 2 of the act-instruction of RGTI-16 dated 11/16/2001 No. 74 established the deadline for withdrawing the AHU for reconstruction - no later than 01/01/2002. The draft city budget for 2002 included an article on the beginning of funding for reconstruction work, but this article was excluded when the budget was approved.
During the next inspection in March 2002, the inspectors of RGTI-16 and Rostrudinspektsii stopped the operation of refrigerator No. 1 (order No. 1/03 dated 27.03.2002). The refrigeration supply of refrigerator No. 1 was stopped from 01.05.2002.
01/29/2003, Deputy Head of RGTI-16 Pomelov R.V. issued "Instruction No. 1/2 for the suspension of work (facility)", according to which it is necessary to stop the operation of AHU MUP "Food Plant" from 30.01.2003. it is impossible to produce kvass in the summer. As a result, 138 people (55% of the payroll of the enterprise) are simultaneously left without work, and the very existence of the food processing plant is called into question.
A similar situation is possible in the case of the implementation of the AHU reconstruction project, because a complete replacement of equipment, pipelines, a change in the building structures of the building is not possible without decommissioning the installation for a long time.
Under these conditions, the need for the development of the Program for the technical re-equipment of the MUP "Food Plant" is obvious, which provides for an alternative to the existing option for the reconstruction of the entire refrigeration supply system for food processing plants, namely: a gradual transition to autonomous refrigeration using a safer refrigerant - freon.
2. Main goals, objectives and terms of the Program implementation
The main goal of the Program is the development and implementation of an alternative option for the reconstruction of the refrigeration system of a food processing plant with a phased transition to autonomous supply of cold to the enterprise's production facilities using a safer refrigerant, compared to ammonia, freon.
Implementation of the Program will solve the following tasks:
Bringing the refrigeration system of the MUP "Food Plant" in line with the requirements of the legislation of the Russian Federation in the field of industrial safety.
Liquidation of a chemically hazardous production facility in a residential part of the city. Reducing the risk of man-made emergencies through the use of freon instead of ammonia in refrigeration equipment. (The existing AHU contains 10 tons of ammonia).
Phased reconstruction of the refrigeration system, which eliminates the need for long production shutdowns and downtime.
Radical renewal of the equipment fleet of the ice cream shop, in contrast to the existing version of the reconstruction of the AHU, where this was not envisaged.
Terms of the Program implementation: 2004 - 2007.
Measures for the implementation of the Program
To implement the Program, a set of measures is provided that allow:
ensure compliance with the requirements of regulatory documents governing such work;
to avoid long stoppages of production during the reconstruction, and, therefore, not to reduce the volume of output and not worsen the financial and economic performance of the enterprise;
ensure stable and planned funding for each event.
| № p/n | Events | Period of execution | Need for funding |
| 1 | Designing an autonomous refrigeration supply system for the production of MUE "Food Plant", conducting marketing research on the refrigeration equipment market, choosing the best option, the final determination of the cost of the necessary refrigeration equipment, as well as the cost of installation and commissioning at each stage of the Program implementation | 2004 | 300 thousand rubles |
| 2 | Transfer of three refrigerating chambers of the bakery and confectionery industries and three refrigerating chambers of the ice cream shop to autonomous refrigeration using freon equipment, installation, commissioning. | 2005 year | 1.5 million rubles |
| 3 | Replacement of ammonia process equipment in the ice cream shop with freon equipment, installation, commissioning | 2006 | 8.0 million rubles |
| 4 | Transfer of the site for the production of kvass to autonomous refrigeration with the use of freon-powered refrigeration equipment, installation, commissioning. | 2007 | 5.0 million rubles |
| 5 | Final decommissioning of the existing ammonia refrigeration plant, dismantling of equipment and pipelines. | 2007 | 0.5 million rubles |
| Total | 15.3 million rubles |
Resource support of the Program
The most important condition for the implementation of the Program is stable financing of each stage.
The financial support of the Program will be carried out at the expense of:
city budget;
own funds of MUP "Food Plant".
The phased implementation of the Program will make it possible to calculate in advance the amount of funding for each stage, to determine the share of funding for each source, specifically, at each stage of implementation. This will also make it possible to make proposals for the inclusion in the city budget of the relevant items of expenditure for the corresponding financial year in a planned manner.
The volume of expenses for the implementation of the Program is determined, approximately, in the amount of 15.3 million rubles, of which: funds of the enterprise - 1.0 million rubles, budgetary funds - 14.3 million rubles.
The final amount of financial investments for the implementation of the Program as a whole and for each event separately will be determined after the implementation of event No. 1, i.e. after the completion of the development of design estimates.
Implementation mechanisms and control over the progress of the Program
Mechanisms for the implementation of the Program and control over the progress of its implementation are based on existing system administrative and economic subordination of municipal enterprises to the City Administration, as well as on the existing scheme of interaction between the City Administration and the Duma.
The customer of the Program is the City Administration. The main investor of the Program is the UKS Administration with the participation of MUP "Food Plant". The executor of the Program is determined based on the results of the competition in accordance with the current rules for the distribution of the municipal order.
Control over the implementation of the Program is carried out by:
City Administration;
Duma of Sarov;
management of MUP "Food Plant";
Regional Mining and Technical Inspectorate (RGTI-16).
Financial control is carried out in accordance with the established procedure by the city finance department.
The current management of the implementation of the Program at each stage is carried out by the Municipal Unitary Enterprise "Food Plant".
Socio-economic efficiency of the Program
Full implementation of the Program will ensure the conditions for sustainable and safe operation of the refrigeration supply system for the production of the food processing plant and the entire enterprise as a whole. The use of new equipment and technologies in the production of ice cream will allow, in the face of fierce competition, to expand the range, maintain, and in the future increase the volume of products. Minimizes the risk of man-made emergencies during operation new system refrigeration supply, the consequences of which could affect some of the houses in a nearby residential area. Further stable operation of all industries using cold will be ensured: bakery, confectionery, ice cream and kvass production, which will allow not to reduce the volume of food production, which is in constant steady demand among city residents.
All the above results of the implementation of the Program will contribute to the further maintenance of the stability of the social climate in the city of Sarov.
Economic efficiency from the implementation of the Program is determined by a significant reduction in operating costs when introducing an autonomous refrigeration system using freon, namely:
a significant reduction, by 2–2.5 times, in the energy intensity of refrigeration equipment;
reduction of water consumption during the production of cold;
reducing the number of service personnel, reducing wage costs;
reduction in the range and cost of consumables and repair materials and spare parts;
reduction of payments to the environmental fund for the release of HCS into the atmosphere.
Based on the analysis technical condition fixed assets of the enterprise, taking into account the actual, moral and physical depreciation of it, the data of the balance sheet, the enterprise has developed detailed program re-equipment and renewal of production for 2012 and subsequent periods until 2015. The need for the necessary funds was calculated.
The action plan for the development of investment activities of Novopolotskzhelezobeton OJSC in 2012 is as follows:
| Construction of a mini-CHP with the installation of an energy source for combined production of electricity and heat, a steam back-pressure turbine | 5200, 5200-own facilities | Obtaining heat and electricity own. production, 17 new jobs. | |||
| Reconstruction of the 1st polygon of the molding shop No. 1 | 200 bank loans | Increasing the output of competitive products | |||
| Modernization and reconstruction of molding shops | 100 bank loans | ||||
| Current repair of intra-factory roads, sites | 200 bank loans | Landscaping | |||
| Further development of the use of equipment "frame house" | 30 bank loans | Increasing the output of competitive, export-oriented products | |||
| Modernization of the Tensiland formless molding line | 1300 - bank loans | Increasing the output of competitive, export-oriented products | |||
| Acquisition of basic construction machines and mechanisms | 250 bank loans | Sand Quality Improvements |
1. Construction of a mini-CHP with the installation of an energy source for the combined production of electricity and heat (a business plan for an investment project has been developed).
The main idea of the investment project
Due to the fact that JSC "Novopolotskzhelezobeton" at the stage of its formation was part of Trust No. 16, the power supply scheme was built and developed as a single electric power complex.
At present, the power supply scheme for the entire industrial zone, gravitating towards JSC Novopolotskzhelezobeton, consists of:
Head step-down substation (GPP) 110/35/6KV, which is on the balance sheet of OJSC Novopolotskzhelezobeton;
29 transformer substations 6 / 0.4 kV with a unit capacity of 160 to 1000 KVA, which are both on the balance sheet of JSC "Novopolotskzhelezobeton" of the enterprise, and on the balance sheet of other enterprises;
High voltage cable lines.
The power supply system of transformer substations is a ring circuit that provides the necessary reliability (redundancy) of the 6KV power grid. to limit short-circuit currents in ring circuits, there are breaks at TP 6 / 0.4 and part of KL-6KL is in a “hot” reserve.
The scheme has 2 powerful distribution points (centers) RP-30, switchgear 6KV of the substation "Promploshchadka" with all types of protection installed: overcurrent protection, current cutoff, "earth protection",
Heat supply of Novopolotskzhelezobeton OJSC is carried out by two types of heat carrier: steam and heating water.
Steam heating is carried out from the Novopolotsk CHPP through the networks of JSC "Polymir" by double reduction of steam:
The total length of the steam lines is:
ü DN 400 - 1841m;
ü DN 300 - 400m;
ü DU 350 - 70M.
As a result of long-term operation, the thermal insulation of steam pipelines has largely lost its heat-insulating properties, and the loss of steam thermal energy has sharply increased.
Heat supply with heating water for the needs of heating is carried out from the thermal route "CHP-8th microdistrict of the city".
The total length of the pipelines is:
ü DN 300 - 160m;
ü DN 250 - 1398m;
ü DU 200 - 800M
As a result of long-term operation, the thermal insulation of heating water pipelines has also largely lost its thermal insulation properties, and thus, the loss of thermal energy of heating water has sharply increased.
During the implementation of this investment project, it is planned to build a mini-CHP on the existing production facilities of JSC Novopolotskzhelezobeton, which will lead to a change in the existing electricity and heat supply of the enterprise.
Fundamental technological solutions
This project provides for the creation of an energy technology complex consisting of one microturbine power unit with an electric power of 600 kW, four Viessmann Vitomax 200NS steam boilers, three of which have a capacity of 2.9 and one 5 tons of steam per hour, as well as a steam counter-pressure turbine with an electric power of 180 kW and other auxiliary equipment to ensure the functioning of the energy complex. The quality of water directed to steam production is ensured by a water treatment station (15 m 3 /hour) and a nutrient deaeration plant (15 m 3 /hour). Energy production at mini-CHP is planned to be carried out in automatic mode. The complex is connected to the existing communications, which are remote from the energy complex at a small distance, the final choice of connection points to the communications is determined by the project.
The steam boiler house is located on the freed area of the existing compressor building, which has a free building volume of 18x18x10.8 m for the installation of boiler equipment.
The internal volume of the boiler room houses four steam boilers with auxiliary equipment, chemical water treatment equipment and a group of pumps. On the second tier of the premises there is an operator's room, a gas distribution unit (GRU), heat exchange equipment, a feed water tank and a deaerator. In the room adjacent to the boiler room, there is a turbine room, where a steam turbine with an electric generator is located. Outside the building, a C600 INDKG power unit is installed based on three microturbines in a container version and a chimney.
The preliminary layout of the first tier of the mini-CHP is given.
The area of the premises allows the installation of boilers without violating the requirements of the Rules for the Design and Safe Operation of Steam and Hot Water Boilers. UE "DIECOS", 2007. When installing boilers, the distance between the boilers and the wall of the boiler room is more than 1.5 meters, which complies with the above rules. The final layout of the energy complex will be determined by the project.
Four Viessmann Vitomax 200-HS steam boilers are designed to generate thermal energy using gaseous fuels. The low level of emissions of harmful substances is ensured by the three-way gas ducts of the boiler block at a low heat density of the combustion chamber.
– Preliminary layout of the first tier of a mini-CHP
The main technical characteristics of the steam boilers planned for installation in the boiler house are given.
Specifications steam boiler Vitomax 200-HS
The cogeneration power plant is designed to cover base chart electricity consumption by the enterprise, as well as for supplying the production of hollow flooring slabs (Tensiland line) and domestic needs of JSC Novopolotskzhelezobeton with thermal energy in the form of hot water.
The power plant is a power unit consisting of three microturbine generators with an electric power of 200 kW each and a heat recovery boiler.
The power unit of the C600 INDKG model of the CAPSTONE company (USA) is made in a container version and is located in the immediate vicinity of the boiler house. The thermal schemes of the power unit and the boiler house are combined into a single thermal scheme, where they mutually complement each other.
The technical characteristics of the power unit of the C600 INDKG model are presented.
Technical characteristics of the power unit model "C600 INDKG" company "CAPSTONE" (USA)
Turbine generator set TGU R-0.8-1.7/0.7 is designed to generate electricity through the use of steam potential. The steam turbine is made in a single-cylinder design on a common foundation frame with a generator. The turbine is designed for continuous continuous operation of at least 8000 hours per year. Turbine power variation range from 0 to 110% of the nominal value. TSU is manufactured according to TU VU 191297032.001-2010 “Energy-saving low power turbines. Specifications". The manufacturer of the TGU R-0.18-1.7 / 0.7 turbogenerator set is ChPTUE United Energy Company (Republic of Belarus).
Technical characteristics of the TGU turbogenerator set
P-0.18-1.7/0.7 are presented in Table 5.3.
Technical characteristics of the TGU R-0.18-1.7/0.7 turbogenerator set
Fresh steam from the boilers with a pressure of 18 bar in the amount of 8 tons per hour enters the turbogenerator through a common manifold. The above volume of steam at a temperature of 230°C ensures the operation of the steam turbine at the maximum possible load. TGU generation of electricity is carried out depending on the consumption of steam by consumers. During the operation of the turbogenerator set, its expected load will be 83.87% of the nominal value.
The steam that has been exhausted in the turbogenerator at a pressure of 7 bar is directed to technological needs. The steam pressure of 7 bar is determined based on the needs of the KPD plant, taking into account the pressure drop during its transport. Also, the reconstruction of the on-site steam network planned for JSC Novopolotskzhelezobeton will make it possible to deliver steam at a pressure of 7 bar through a smaller section of the steam pipeline, which reduces capital investments in the reconstruction of the steam network, and by reducing the area of contact of the steam, it reduces heat transport losses through the pipeline wall.
For the long-term competitive development of any machine-building enterprise, it is necessary not only to create unique equipment, but also to be successful among the leading companies in its industry. The competitiveness of an enterprise depends on how the technical process proceeds on it, and its organization directly depends on the quality of the equipment used. That is why all industrial companies pay special attention to the implementation of complex projects for the purchase of modern high-tech equipment. The bureau of equipment and technical equipment is engaged in updating the machine park at AMZ OJSC (Arzamas Machine-Building Plant). Oleg Vlasov, head of the bureau, shared with us about the current state of affairs at the enterprise and immediate plans in the field of technical re-equipment.
- Oleg Evgenyevich, what work on technical re-equipment has already been carried out at the enterprise this year?
As part of the investment program of the military-industrial complex for 2014 in the field of technical re-equipment, AMZ OJSC planned to purchase new efficient equipment. This year, we have already purchased a band saw for the harvesting area, which allows us to speed up the process of creating products, while maintaining high accuracy. Also a machine for laser cutting of metal, it is already operating in the automatic press shop. We have had similar equipment at MSC-8 for several years now. The motivation for purchasing the PAC laser was the price of expensive press dies. In order not to wait for the manufacture and repair of the necessary dies, it was decided to buy and install laser equipment in this workshop. Also, training was carried out for two adjusters who are successfully working there today.
A CNC turning and machining center has been purchased for the manufacture of the “headlight-spotlight” product, which is installed on the Tiger armored car. It will arrive at the plant at the end of October.
Purchased a plotter for cutting rubber gaskets. At MSC-2, there was a problem with cutting rubber products: before that, the site used a low-power laser purchased 5 years ago, which was beyond the strength of today's labor-intensive production pace. For a long time we have been selecting equipment that could effectively cope with this task. And now the activity of the site has significantly intensified.
Currently, MSC-4 is carrying out commissioning of a horizontal milling machining center, which will be used for the production of levers intended for assembling new advanced models of armored vehicles. The Moscow-based company Soldrim, which is one of the largest suppliers of industrial equipment in Russia, acted as a business partner.
- How is the decision to purchase equipment carried out and how does this process proceed?
The technological department is working on the issue of launching new products into mass production, finds out what equipment needs to be purchased for this. A technological chain is built, a list of machines is formed and the expediency of their purchase is determined. After that, the terms of reference are drawn up, work is carried out with potential suppliers. As a rule, offers come from about 15 firms. The technical management selects the most acceptable and suitable manufacturers for the plant in accordance with the quality and price policy. In conclusion, an open tender is held, which is attended by managers and technical specialists supplier companies, where they present their equipment, answer our questions. After that, the tender committee of the enterprise decides on the acquisition of the most suitable samples. The final point is the statement decision tender committee of VPK LLC and signing an agreement with a supplier.
- How to choose the right equipment and not make a mistake?
When choosing the equipment to be purchased, some suppliers are ready to provide their equipment to the enterprise completely free of charge for the purpose of direct operation at the production site and the subsequent decision to purchase it. We took advantage of one of these opportunities: a turning and machining center was delivered to the plant for test use. Within a month, the equipment will be actively operated by MSC-8 employees to determine its quality characteristics and production capabilities.
- How does the purchase of new equipment help to solve problems in production?
We purchase new high-tech equipment, which reduces the time for manufacturing products and increases their quality. In a word, new equipment should fulfill the tasks facing the enterprise today.
The implementation of technical re-equipment projects allows expanding the prospects for production, speeding up its topics, increasing efficiency and gaining new opportunities. There is no doubt that investments in new technologies justify themselves. The plant is developing dynamically, orders are received, contracts are signed, and, accordingly, production volumes are growing. In order to fulfill them in a timely manner and with high quality, today it is simply necessary to update the machine park. After all, one CNC machine can easily replace several old ones at once, close the shortage of qualified personnel, as well as free up space and improve production culture.
- How does the plant staff cope with the work on the new modern equipment?
Along with the purchase of a new machine, staff training is carried out. We buy high-tech equipment, which requires real professionals to work on. The company has specialists who have received the initial basic knowledge of working with CNC machines in schools and technical schools. And this is quite a significant factor. For example, laser equipment has been operating in MSC-8 for about 5 years. When buying a laser in the PAC, the specialists of the eighth workshop took part in the training of operators and observed the operation of the new machine. When buying more narrowly specific equipment, specialists undergo mandatory training by the supplier's service department.
It is also worth noting that modern and high-tech equipment requires special care to maintain its precise capabilities, namely, it is necessary to regularly clean it, wipe it, carry out autonomous maintenance, and observe the culture of production. The administration of the plant has repeatedly noted cases of neglect of these rules by workers and foremen of some workshops, in particular MSC-1 and MSC-8, and raised these issues for discussion. Is it worth buying expensive equipment and not following the basic rules for caring for it? I think everyone knows the answer! Therefore, in addition to training personnel to work on new machines, it is also necessary to instill the skills of their maintenance after operation, and the foremen and heads of workshops must strictly monitor this.
- What are the plans for the technical re-equipment of the plant in the near future?
AT this moment the supplier of turning equipment is determined. The plant plans to purchase 12 units of CNC lathes in late 2014 - early 2015. This high-tech equipment will maximize the quality of manufactured products and solve the problem with the shortage of turners.
