Three effective, in our opinion, by the development of piles and pile foundations in construction are technical solutions from the Department of Construction Technology of Brest State Technical University: pile support (patent of the Republic of Belarus for a utility model No. 8603), a bored pile (patent No. 8370) and the third development - a pile (application for a patent of the Republic of Belarus).
The pile support, in comparison with others of a similar purpose, is very simple to manufacture, minimally metal intensive (only the barrel is metal), cheap and technologically advanced to manufacture. On such supports you can erect fences, gates, build country houses, garden buildings and a wide variety of other above-ground structures.
Before being immersed in the well, the pile support is a profile metal pipe 1 with drop-down blades 2 made from sections of the wall cut with longitudinal slots 3 at the lower end of the pipe (Fig. 1). The pipe 1 itself is made of a square box-shaped cross-section (patent No. 8603). It can also be made with a rectangular box section. Both types of box profiles are produced by the domestic industry and they are cheaper than round metal pipes, approximately equal to box profiles in terms of the cross-sectional area of the trunk.
Longitudinal slots 3 are made on the side ribs of the pipe 1 using a milling cutter or cutter on a milling or cutting machine, a gas or kerosene cutter, or even on a sharpening (grinding) machine, as well as manually using a hacksaw. Moreover, the greater the length of the blades 2 and the length of the longitudinal slots 3, the greater the opening of the blades in the well will be and the greater the broadening will be created in the ground.
After drilling a well in the ground with any tool, mechanism, device or machine of the required depth and a larger (compared to the cross-sectional dimensions of the pipe 1) diameter, a lost shoe 4, previously selected from natural or artificial stone in the form of a round boulder or a spherical body, and then begin to open the blades 2 by driving in the pipe 1 (Fig. 2). Due to the large cross-sectional dimensions of the shoe 4 (compared to the cross-sectional dimensions of the pipe 1), but smaller compared to the diameter of the well, the blades 2 of the pipe 1 begin to slide and move apart along the shoe 4 (boulder) to the sides and crash into the walls of the well , creating a widening in it and the pile support itself. After sufficient opening of the blades 2 in the well (which can be judged visually and instrumentally by the sediment of the pipe 1 in the well), they begin layer-by-layer backfilling of the well with soil, sand, and crushed stone with careful compaction of each layer. As a result, a pile support is formed in the soil with a very high bearing capacity on the foundation soil under the influence of both vertical and horizontal pressing loads.
BrSTU has also developed the second (patent of the Republic of Belarus No. 8370) and third (patent application of the Republic of Belarus) options for constructing pile supports (drilled pile and pile), which differ from the first in the shape of the shaft and the material of the pile.
In a bored pile, the trunk is made round from a metal pipe 1 with opening blades 2, made from sections of the wall cut with longitudinal slots 3 at the lower end of the trunk (Fig. 3). Subsequently, under the influence of driving, the blades 2 in the well open, turning into a pile support in the ground (Fig. 4).
In the pile, the trunk 1 is made of wood from round timber, and the opening blades 2 are made of metal, attached to the trunk with nails or screws 5 (Fig. 5). The opening of the blades 2 in the well is also carried out using the driving method (Fig. 6).
In other respects, the designs of the pile support, bored pile and pile are similar, and the technologies for installing them into wells pre-drilled in the ground are similar.
Under certain conditions, all three designs can bring a significant economic effect from implementation in construction practice, in particular on soft soils of the Republic of Belarus.
V.P. Chernyuk, Associate Professor, Department of Construction Technology
Brest State Technical University, Ph.D.
4.2. Rationalization proposals as an integral part of the enterprise’s activities
The rationalization movement in Tatneft has existed almost since the very inception of the company. Even today, management does its best to stimulate its employees to creative work of thought. The planned approach also plays an important role in this - every year the management departments are given the number of improvement proposals that need to be introduced into production. And it must be said that NGDU Bavlyneft consistently not only fulfills, but also exceeds this plan.
The importance of innovation cannot be overestimated. This gives development to the production process, improves working conditions, increases its safety, is reflected in the rating of the workshop and affects the material and moral incentives of workers. The economic effect of innovations is also important. According to rough calculations, the rationalization proposals made it possible to save about 400 thousand rubles. At the same time, not all successful ideas introduced into production can be calculated in monetary terms, since some of them are aimed at improving working conditions.
4.3. Economic efficiency from the implementation of otm, gtm
Every year, oil and gas producing enterprises develop and approve measures for energy efficient economy. One of these measures is the introduction of pumps with shortened suspension (reducing the depth of descent of downhole pumps) in production wells.
I At NGDU "Bavlyneft" some wells are in operation that operate at high dynamic levels. Reducing the suspension depth of pumps in these wells leads to a reduction in energy costs for lifting liquid, and optimal operation of deep-well pumping equipment is achieved.
The layout is designed to increase the between-repair period of operation of sucker rod pumping equipment for oil production from oil wells, and helps to increase oil production.
The performance indicators of wells before the introduction of pumps with shortened suspension were taken as a basis for comparison.
Table 4.2.
Introduction of pumps with shortened suspension
|
Name of indicators |
Basic option |
New option |
Deviation |
|||
|
Scope of implementation | ||||||
|
Suspension lowering depth | ||||||
|
Duration of hoisting operations | ||||||
|
Electricity consumption | ||||||
|
Energy costs |
thousand rubles/year | |||||
|
Specific amount of ORS at wells | ||||||
As a result of the introduction of pumps with shortened suspension, changes in indicators occurred: the depth of suspension descent was reduced by 11%, which amounted to 120 m, and the duration of lowering and lifting operations was reduced by 5%, which amounted to 1 hour. Electricity costs decreased by 8.4 thousand rubles/year, which amounted to 4683.3 kW/h, that is, by 8.7%. The volume of implementation has remained unchanged, and the technology for testing existing wells equipped with pumps with shortened suspension is carried out without the involvement of well drilling crews.
Table 4.3.
Calculation of the economic effect of introducing pumps with shortened suspension
|
Name of indicators |
Meaning |
||
|
ORS costs | |||
|
Resuscitation costs | |||
|
Operating cost savings | |||
|
Income tax | |||
|
Income tax | |||
|
Net profit | |||
|
Duration of work | |||
|
Main and additional wages, with social security contributions |
The results of the calculations show that operating cost savings amount to 741.7 thousand rubles and net profit – 593.4 thousand rubles.
Thus, the economic effect is achieved through:
reducing energy consumption costs;
reducing the height of liquid rise.
Using this method, the enterprise fulfills its objectives in the field of cost savings in terms of resource conservation and an economic effect is achieved.
II Application of variable heating mode, with a decrease in temperature at night and on weekends in enterprise buildings:
automatic regulation of thermal energy consumption is established, which significantly increases the efficiency of its use;
comfortable indoor conditions and uniform distribution of thermal energy throughout the building are ensured;
the temperature of the return network water is maintained according to the schedule;
heat supply modes for buildings are selected and adjusted;
any temperature regime is set and maintained, for example, the temperature in the building is lowered in order to save money during non-working hours or on weekends;
Excessive heating is excluded in the autumn and spring periods;
the hydraulic mode of the heat supply system is improved.
For comparison, we take automatic regulation of thermal energy consumption and the usual mode of heat supply to buildings according to the temperature schedule (Table 4.4).
Table 4.4
|
Name of indicators |
Unit measurements |
Option basic normal heat supply mode |
New option automatic regulation |
Saving |
|||
|
Thermal energy | |||||||
|
Net profit | |||||||
III Replacement of transformers with higher power with smaller ones
Transformers with increased power are installed at oil production facilities. Replacing them with a lower power will reduce the no-load losses of the transformer and ensure a reduction in energy consumption.
Depending on the load, power losses of power transformers amount to about 4% of the rated power. Replacing transformers with a power of 100 kW by 63 kW, and 63 kW by 25 kW will reduce electricity losses.
25 kW transformers are installed instead of 63 kW transformers, which then replace transformers with a power of 100 kW; released 100 kW transformers are transferred to the reserve fund or installed at newly commissioned facilities, or sold (Table 4.5).
Table 4.5
Technical and economic advantages
|
Name of indicators |
Unit measurements |
Basic option |
New option |
Saving |
|
Transformer replacement | ||||
|
Transmission power of 100 kVA is released | ||||
|
Cost of transfers. 25kVA - 5 pcs. | ||||
|
Electricity | ||||
|
Electricity | ||||
|
Replacement costs | ||||
|
Increased depreciation costs | ||||
|
Reduced operating costs | ||||
|
Net profit |
thousand rubles |
Table 4.6
Analysis of energy saving measures aimed at saving electricity
|
Name of events |
Energy Saving |
Economic |
||
|
The use of variable heating mode, reducing the temperature at night and on weekends in the enterprise building | ||||
|
Replacing transformers with more power with less | ||||
An analysis of these two energy conservation measures aimed at saving electricity (Table 4.6) shows the progress achieved in monetary terms. They total more than 1.7 million rubles. With the help of these measures, the enterprise fulfills its goals in the field of energy saving. Thus, an economic effect is achieved.
Electrician of the 5th category of the Teploozersky district of the contact network of the Obluchenskaya power supply distance, Alexander Andreyanov, was awarded a personalized watch of the head of the Far Eastern for the implemented rationalization proposal railway. His device for eliminating broken strings outside the size of the contact wire won the industry competition “Idea of JSC Russian Railways - 2012”. Nowadays they are talking about an insulated rod with cutters not only in the Far East, but throughout the entire road network.
The contact network consists of many elements - strings. If one of them breaks and hangs oversized, this impedes the movement of the rolling stock. To eliminate the break, previously it was necessary to take “windows”. And they, in turn, waited until 5 o’clock.
“Once, the chief engineer of ECh-1, Ivan Sergeevich Tolstokulakov, and I had a conversation about how the situation needed to be changed,” said Alexander Andreyanov. – In principle, he and I invented it together. I first made one thing, then improved it so that the device worked flawlessly. It took me about a month to do everything.
This is practically all that we managed to learn from Alexander Vasilyevich himself. As his colleagues said, he does not like to brag or talk a lot.
– Alexander Vasilyevich is a man of action. “His hands are golden,” this is how the head of the EChK, Vitaly Yakimov, described the employee. – This is not his first rationalization proposal and invention. To start working on one, he will have to prepare for a month: he will think about everything, consult with the chief engineer Ivan Sergeevich. Until Alexander Vasilyevich decides that the device is ready for use, it is better not to ask him about it and not to rush it.
Information sheets on a device for eliminating broken strings outside the size of the contact wire have been distributed throughout the network. A request has already been received from the Sverdlovsk road.
– Everything ingenious is simple. The device looks like powerful scissors that cut through wire. They are attached to a long rod (it allows you to work under voltage). During operation, you need to hold it with both hands,” Ivan Tolstokulakov described the invention. – The cost of its production is only 3 thousand 838 rubles 28 kopecks, including labor costs. And the annual economic effect is 90 thousand 533 rubles.
The technical department of the distance explained that at the time of submitting documents for the award of Alexander Andreyanov, the annual effect was calculated only for one unit and without taking into account train work (train stopping, train delays, reducing section speed, traveling a section with a lowered pantograph, etc.). In fact, the economic effect of using this development over the entire distance will be significantly higher.
“This device has already been implemented at six distances and works without failures,” said Lyudmila Sunmina, leading engineer of the technical department of ECh-1. – Before the introduction of this simple device, when using an emergency window, the total cost for one damage sometimes exceeded 100 thousand rubles.
Previously, in order for a train to pass a place with oversized strings, it was necessary to stop to lower the pantograph. And, of course, it was necessary to warn the driver about this in time.
To remove oversized wires, the team had to go to the “windows”. It consisted of at least 4 people, including signalmen. Now “windows” are not needed for this type of work. The device allows a team of two people to remove oversized strings. In this case, trains can run with raised pantographs.
Today, all divisions of the distance are equipped with such “scissors”. They are made in workshops according to the drawings of Alexander Andreyanov.
E. SHAKOV, employee of the newspaper “Youth of Azerbaijan”
“Write about Nusrat Abdulov from Novobakinsky,” suggested the secretary of the Shaumyan district Komsomol committee, Fazil Orujov. - The guy has a golden head, I know that well. We worked together at the same factory.
Orudzhev recently visited the district committee. Before that, he was a secretary at the Novobakino Oil Refinery named after Vladimir Ilyich.
The plant is only 18 years old. The age is small, “Komsomol”. However, maturity is evidenced by the Order of the October Revolution, received by this enterprise of communist labor for its successes in the Eighth Five-Year Plan.
And the plant began the ninth five-year plan at the same fast pace, completing the plan for its first year ahead of schedule. This is a considerable merit of the factory youth. There are a lot of young people at the plant. One of the drummers is Komsomol member Nusrat Abdulov.
Our guest is the newspaper of the Central Committee of the Komsomol of the Azerbaijan SSR
"THE YOUTH OF AZERBAIJAN"
Nusrat is now a senior electrical engineer at the Central Control Room. And six years ago, when I came to NBNZ after graduating from the institute, they sent him as an electrician to the third workshop.
I was lucky, they told me, Nusrat recalls, straight from the institute bench - and to a leadership position: 22 fitters under the command. And I, although I worked for a year and a half at one of the factories during my studies, to be honest, I was a little afraid. The third workshop is sometimes called a “factory within a factory.” The installations are huge. I came and saw that there were two engines. Each one goes to the ceiling of this room. Power - 3.5 thousand kW, speed - three thousand revolutions per minute, I have never encountered anything like this before, so I was scared. True, he didn’t show it. And after a few days there was no more fear - I got used to it.
Nus-rat and I have been talking for an hour now at the factory Komsomol committee. He heads the manufacturing sector here. He brought me here after a short tour of his facility - the central control room, where he manages the adjustment work. He showed a lot of automation and telemechanics devices that control, regulate and measure
parameters of a variety of objects included in a single system. And there are such objects at the plant, apparently and invisible: installations for catalytic cracking, primary oil distillation, polymerization, and a catalyst factory. A complex, large farm, scattered over many kilometers. It consumes a huge amount of energy every day.
Previously without remote control it was a little tight. Imagine for a moment that one of the installations lost power. The operator calls the electrician, who reports to the district dispatcher, who, in turn, reports to the chief dispatcher. The chief sends a car with a team of electricians. It will take a long time before they get to the installation. And every lost minute turns into tons of lost oil product. After all, on average, the installation produces about 200 tons per hour.
It took a long time for the plant to begin implementing a dispatch system. There was a lack of experience; such systems had not yet been used in oil refining.
One day, Abdulov was summoned by the director of the plant, Firidun Iskenderovich Zeynalov.
Twenty-six of them were classified as group “B” - engineering and technical ideas without a calculated economic effect or with an effect of up to 60 thousand rubles per year. Most often, these are proposals to improve reliability, maintainability, increase the service life of equipment components, and eliminate design flaws - that is, what repairmen are traditionally strong at.
One of the proposals was made by master Vasily Mineev and repairmen Igor Moldovan and Alexey Rebrovsky. “Less fuss - more action!” - thought the innovators, fundamentally changing the approach to organizing a repairman’s workplace.
“Less fuss - more action!” - the innovators decided, changing the approach to organizing the workplace
When we inspect or repair household window air conditioners and split systems, we have to constantly “circle” around the equipment. Either on the one hand you need to do something, then on the other you need to perform certain actions. “This is inconvenient,” one of its authors, Vasily Mineev, comments on the idea. - We decided to make a stand from a metal sheet and a profile corner. Its design will be divided into two zones, one of which, fixed on bearings, will rotate together with the unit installed on it that requires repair.
The design is convenient to use both when inspecting and repairing equipment components, and when performing post-repair testing. The rotating part of the stand will allow the worker to be in one place, and the equipment installed on the rotating part turns to the repairman with the desired side. In addition to increasing worker comfort when repairing equipment, personnel time and effort are saved and labor safety is improved.
And here is another idea of the same category “B”. GRAT pumping units are used for pumping highly abrasive hydraulic mixtures with high density and elevated temperature(up to 70 °C). It is not surprising that bearing units are one of the most vulnerable points of this unit.
“Double ball bearings are installed in one of the bearing units,” says master Oleg Altakh, one of the implementers of the idea. - But practice has shown that the bearing lubrication system is imperfect: one of the bearings receives less oil than the other.
To solve this problem, we calculated several options and found the optimal one from our point of view,” says senior foreman Maxim Shafransky, co-author of the project. - To improve the quality of operation of the unit, we will make a cut in the keyway in the lower part of the crankcase, through which we will supply oil for the second bearing.
One more interesting idea Repairmen Alexander Bogdanov and Vitaly Kovalintsev and electrician Denis Saprunov offered the same category. They developed a new cooling system for the electrical room of overhead cranes. In the electrical room of the ESPs overhead crane, five transport air conditioners of the KTA brand are installed, cooling the electrical equipment of the crane. Without them, heat-generating operating electronics and hot outside air can heat the room up to +80 ºС.
Air conditioner heat exchangers have a small interfin space; in production conditions they are constantly clogged with dust and dirt, and specialists have to clean radiators daily to restore their heat transfer. We know how to work with this problem, but we believe that it takes unreasonably large number repairmen have time,” says Denis Saprunov. - In addition, it was necessary to restore the balance of the coolers. Our development took into account this aspect of the problem.
Under normal conditions, air conditioners operate in automatic mode: they turn on at a relay command to increase the threshold temperature and turn off, including to allow the main unit - the compressor - to cool down. All five air conditioners must be in operation at the same time, but in practice it is not possible to adjust the temperature sensors for such a system so that all units work and rest for the same amount of time. As a result, some do not turn off for days, while others remain idle.
We proposed to abandon the use of KTA brand transport air conditioners to cool the electrical equipment of overhead cranes and use a different cooling system,” explains Alexander Bogdantsev. - The system can be assembled from elements of various units, which together will create a single reliable source of cold. The heat exchanger is selected so that its interfin space meets our needs. To compress the refrigerant and circulate it in the system, we propose to use a compressor of a hermetically sealed refrigeration unit; moreover, it has high performance and service life. In order to automatically control the functioning of the closed circuit of the heat exchanger in which freon circulates, we will install two thermostatic valves in the system. Next, we equip the freon pipelines with vibration-damping inserts to level out the loads from the operation of the compressor.
The authors of the project propose to mount an external unit, consisting of a frame, a heat exchanger, a receiver, a filter, and an electric motor with a fan, on the roof of the electrical room, and two air coolers, consisting of evaporators, electric motors with fans, will operate inside.
As a result of the implementation of this measure, the labor intensity of servicing air conditioners will be significantly reduced, their service life will increase, and the electrical equipment of the crane will be cooled more evenly and efficiently.
Let us note that every employee of Ural Steel has the opportunity to participate in the Idea Factory, submit their proposal, which can bring additional profit to the plant or save resources, increase labor productivity and pay more attention to labor protection and industrial safety.
Igor Sosnovsky, Photo by Rezeda Yaubasarova
