PROCUREMENT AND INSTALLATION OF A NEW PLANT WITH SENSORS FOR NATURAL GAS DETECTION IN THE DHP ISTOK
Carrying out of this investment is of an exceptional importance for the safety of the the district heating plant (DHP), the employees, and the wider surrounding of the DHP. The existing plant for detection of natural gas leakage in the DHP Istok was procured and installed in 1997, when the heating plant was gasified. Due to the obsolescence of the equipment, the manufacturer stopped producing spare parts, which made servicing more difficult and put at risk the proper functioning of the natural gas detection system.
The investment included procurement and installation a new plant for natural gas detection, new detection sensors, 22 in total, located at all critical points in the heating plant, procurement and installation of new electrical cables to connect the plant with sensors and new fireproof canals and stainless steel pipes for laying cables. Also, an additional number of sensors with brackets were placed in several places which according to the previously prepared Elaborate for protection against fire, explosion and dangerous substances, were to be placed, but could not be placed at the old plant due to the limited number of connected sensors.
The realization of this investment enabled:
- increasing the safety of the employees and the surroundings of the heating plant;
- increasing the technological safety of the equipment in the heating plant;
- increasing the reliability of the heat production process in the heating plant and
- fulfilment of the legal obligations for burning natural gas in boilers.
The equipment for carrying out of this investment was procured by the renowned manufacturer Duran (manufacturer of this type of equipment for Siemens). The installation of the plant, sensors for detection of natural gas leakage and other equipment was performed and the plant was put into operation by the company Tehnoinspekt.
RECONSTRUCTION OF HYDRANT WATER SUPPLY NETWORK IN DHP ZAPAD
The hydrant water supply network in DHP Zapad as a part of the equipment intended for fire fight dates since the beginnings of the district heating plant with constant upgrades with additional hydrant spots. The regular annual inspection of the functionality of the hydrant system was determined that a couple of hydrants perform below their technical requirements In terms of water pressure during operation.
This condition was obvious at the foam operated hydrants which were installed on the top floor of the district heating plant, i.e. when put to operation they could not form the foam. Because of this, the company decided to enquire a project solution which will provide replacement of the malfunctioning hydrants with new ones. The project covered preparation of special firefight room, installation of firefight pumps and correction of the hydrant pipelines.
The newly prepared firefight room is in line with all standards for such type of object, with appropriate fireproof doors and walls. Inside the room are located the firefight pumps along with appropriate automation equipment for provision of continuous water pressure inside the system. The cables have are fire insulated and are appropriately installed in fireproof canals. The holes inside the walls are fireproof and done with protected pipes.
The realization of this project provided:
- Integration of the hydrant system into the overall firefight system of the district heating plant,
- Increased safety of the plant, employees and the area around the plant,
- Increased reliability of the process of heat production and
- Fulfillment of the legal obligation for construction and use of such firefight systems.
The firefight pumps and the equipment are a product of the well established company Calpeda and the installation and commissioning of the system was performed by the company Turboinzenering, Skopje.
PRODUCTION AND INSTALLATION OF ACCESS PLATFORMS TO CONTROL EXTRACTION PIPES FOR NATURAL GAS IN DHP ISTOK
With the gasification of the DHP Istok in the nineties, the control exhaust pipes for natural gas from the gas installation, as well as the exhaust pipes from the safety valves and the block valves of the gas trains, were installed on all four sides of the heating plant. Most of them were in inaccessible places, high next to the facade of the heating plant or on the roof of the heating plant. The others, which were closer to the walls of the heating plant, had no access paths or platforms, so portable ladders were used to approach the outlets. Any access to the exhaust control pipes for natural gas was unsafe and risky for the operators.
To solve this serious safety problem, we proceeded to the development of a project solution for grouping all outlet pipes and the development of safe access paths and platforms along the pipes themselves. According to the project, all outlet pipes (total 35) were laid towards the north side of the heating plant and were grouped in two locations. At both locations, two standard platforms with a protective fence and access stairs were made and installed. Each of the outlet pipes was marked with a single mark, and the ends of them were protected with stainless mesh.
The realization of this investment enabled:
- safe access to each exhaust pipe from gas installations and equipment,
- easy and reliable control of the presence of natural gas in gas installations and equipment,
- safe blowing of gas installations and equipment with air and nitrogen before intervention and
- significant improvement of the working conditions of the operators.
The project for this investment was made by the project design company Filbis from Skopje, and the implementation of all activities was awarded to the company Dimce Banjarot from Prilep.
RECONSTRUCTION OF THE PUMP STATION IN DHP ISTOK (THIRD PHASE)
This investment was realized within the project for reconstruction, modernization and increasing of the capacity of the pump station in DHP Istok.
The replaced centrifugal circulation pumps were worn since they were in operation for more than 30 years. They had low efficiency, when compared with the one on the new centrifugal pumps and most of them were not serviceable since their manufacturer stopped producing spare parts given their exploitation period. The first and second phase of the project there was a replacement of two centrifugal circulation pumps with new ones which have superior parameters in terms of efficiency and water flow. The year before there was a procurement of two VFD controlled centrifugal pumps which provide additional water flow of 600 m³/h each on top of the existing one.
This year there was a procurement of two new centrifugal circulation pumps, product by KSB: Etanorm RG 300-400 and Etanorm 400-500. The pumps are installed instead of the existing ones. The old pumps were serviced in multiple occasions and due to that they had increased possibility of failure during operation. The new pumps have 8% higher capacity and they are around 10% more efficient compared to the old ones. At the same time in order to reduce the hydraulic losses, a correction on the connection pipelines for the new circulation pumps was made. For the second stage pump 2/2 there was additional installation of new armature along with electric drive Aumatic. For the first time on the suction side of the pumps, there was installation of compensators on the suction side each new pump in order to reduce the vibrations towards the pipelines.
The realization of the project provided:
- Increased reliability of the pump station in DHP Istok,
- Increased reliability of the pump station in DHP Istok,
- Increased capacity of the pump station in DHP Istok and
- Distributed load among the circulation pumps according to the needs of the heat distribution grid.
The equipment for realization of this investment was procured by the companies KSB and Auma – Germany, ABO Valve – Czech Republic, MIV – Croatia. The replacement of the circulation pumps and the armature was performed by the employees in Proizvodstvo na toplina Balkan Energy DOOEL Skopje and the company Dimce Banjarot. The commissioning was performed by licensed representatives, from the side of the equipment manufacturers.
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MODERNIZATION AND AUTOMATION OF THE WATER REPLENISHMENT SYSTEM ATTHE THRESHOLD OF
DHP ISTOK
The current system for replenishment of water losses in the distribution system was dimensioned according to the water losses in the period before the BEG group took over the activity. With the reduction of losses in recent years, this system was oversized and made irregularities in the operation and large errors in the measured amounts of replenished water in the system. In addition, the daily need to direct the water supply behind the main insulating valves of the threshold heating plant, in conditions of non-automated system, required constant manual manipulation of the valves by operators in very difficult conditions (presence of water, low outside temperatures, reduced number of executors, etc.).
According to the project solution, the existing system was reconstructed, which made a parallel system for water replenishment with smaller dimensions (NO50), with appropriate water flow meters for each main pipeline at the exit of the heating plant. Electric drives were also installed on all six water supply valves, operated from the operator’s desk. The remote control of these valves is provided through the electrical equipment placed in the electrical cabinet, as well as new fireproof canals with cables for connecting the electric drives.
The realization of this investment provided:
- providing reliable and accurate measurement of water quantities for replenishment the losses in the distribution system by DHP Istok,
- automated and remotely controlled water replenishment system and
- significant improvement of the working conditions of the operators.
The newly procured electric drives were procured with the renowned company Brandoni, the project solution was developed by the company BIS Engineering, while the installation of the equipment was done by the employees of PTBE and the external company BMG.
RECONSTRUCTION WITH MODERNIZATION OF THE ELECTRIC DRIVE CONTROL SYSTEM AT THE THRESHOLD OF DHP ZAPAD
From the DHP Zapad to the distribution grid, five main pipelines are connected, 10 pipelines in total. Each of these pipelines has two valves installed to insulate the heating plant from the distribution system. So far, only four valves have been provided with electric drives for remote control, while the other six valves have been equipped with electric drives, but without the possibility of remote control. In conditions of reduced staff in the heating plants and difficult working conditions in the places where the valves are installed and in extreme external meteorological conditions, the constant manual manipulation of the valves was extremely unsafe.
With the realization of this investment, a new electrical cabinet with equipment has been procured and the possibility for installation of additional equipment for five more drives, new electric fireproof canals have been installed and new electric cables were laid with which the electric drives have been connected to the operating desk in the heating plant. The two new electric drives for control of the two by-pass valves NO250 in the heating plant have been connected to the new electric cabinet.
The realization of this investment provided:
- reliable operation of the DHP Zapad,
- continuous maintenance of the required parameters at the threshold of DHP Zapad,
- increasing the efficiency of the employees in the heating plant,
- significant improvement of the working conditions of operators and
- reducing the risk to the equipment and process by human error.
For the realization of this investment, the project was developed by BIS Engineering, while the equipment was installed and put into operation by the external company BMG, with support by the employees of Proizvodstvo na toplina Balkan Energy DOOEL Skopje.
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