PRODUCTION SYSTEM

The production is based on application of innovative technologies and modern automated equipment
providing for high quality of the products.

Sergey Nikolaevich Zhadnov

Director of the modular equipment plant

Total production area comprises 5,000 m2, production capacity – 12 concrete casings per month or 15 metal casings per month.

Manufacturing of modular equipment is organized at the production facilities. The products go through the whole production cycle and are released as fully finished manufactured products. In the course of transformer substations design, choice of construction materials and covering technologies all factors are taken into account which are necessary for the equipment use in Russia, such as mechanical strength, water resistance, seismic stability and fire safety.

Modern electric equipment and the latest developments allow even in emergency situations to provide for reliable operation. No constant service by working staff is required for stable functioning of the produced substations, the system is fully automated. Such equipment is actively used by power men in the course of network complex reconstruction. NIPOM participates in implementation of construction and modernization projects of power supply systems of socially significant facilities with regard to all requirements of power and ecological safety.

Production Technology

Development of metal PTS (Package Transformer Substations) is based on project solutions and typical modules allowing to apply the design technology for archetypes. A typical product line is created based on multiple changes of dimensions within the established limits. This allows for providing for minimum periods of the development, the quality and maximum satisfaction of the customer’s needs.

Modular Buildings Design

Development of the Draft Project of a Modular Building

At this stage working-out of architectural and planning solutions of a future building takes place in accordance with the requirements and wishes of the customer, as well as preliminary estimate of the value of the designed facility. All the preliminarily applied solutions are checked from the point of view of compliance with ecological, sanitary and hygiene, fire safety norms for the purpose of safe environment of the used facility for life and health of people. At this stage of design agreement with the customer of the accepted architectural, planning and construction solutions is realized. If necessary, execution of the questionnaire is carried out and development of the requirements specification. Apart from that, at this stage the customer may make corrections and amendments of the solutions accepted in the draft project.

Execution of the Project Documents

The facility project of fast construction is comprised of several sections. CM (Construction Materials) section represents all necessary information concerning metal construction of the building, loads, used nodes and materials. AS (Architectural Section) or AC (Architecture and Construction) section of the project covers the review of architectural and construction part and describes in detail all the matters regarding external and internal structure of the building. And finally, ES (Engineering Systems) sections of the project cover the matters regarding organization of engineering systems inside of the building which are necessary for life cycle. At this stage, if necessary, the project is added by amendments, it is optimized without deviation from the requirements of the customer’s requirement specification, as well as all documents are prepared allowing to carry out the construction.

Preparation of Working Documents

ОAll the adopted construction and engineering solutions are worked out in detail, which is necessary for production and construction of the facility, as well as the solutions adopted within the project with regard to capabilities of the manufacturing enterprise. At this stage, if necessary, the project is amended, optimized, as well as documents are prepared allowing for carrying out the construction
At all stages and steps of modular buildings PEW (Project Engineering Works) automated design and building constructions calculation systems are applied.

Calculated part of the project is executed with the help of calculation SCAD complex intended for strength analysis of constructions using the finite element method.

Graphics part of the project is executed in 3D design system COMPASS-3D, allowing both to make a graphics part (drawings) of construction documents, and to visualize a 3D model of general view, separate nodes and elements of the product.

Production

Internal logistics is built in accordance with transportation route of material flows which allows for reducing losses of time spent on interoperation tracing and shifting between operations.

Planning of the production is fully automated. Data concerning the structure of the products is collected in PDM-system (system of engineering data management) out of CAD-system (system of construction software) and CAPP-system (technological software). After that the data is exported into ERP-system (system of the plant resources management) in a centralized manner for the purchase of materials and components, own production of parts and nodes. The document flow inside of the plant is carried out within the framework of ECM (electronic document flow system). Authenticity of such documents is proved by user ID and certified electronic signature.

Blanks start their movement from the materials warehouse. As a result, in the process of linear transmission from one operation to another one they are transformed into a fully finished plant-manufactured product in the shipment area. The technological process provides for full production cycle of manufacturing modular PTS including the following stages.

1. Warehousing with the addressed storage.
2. Blank production – cutting of the sketch metal-roll at two-rack belt-sawing machines intended for heavy load modes of cutting and highly productive processing.
3. Assembly and welding operations with application of 14 all-purpose welding tables and semiautomatic welding machines are carried out with the help of semiautomatic welding in the environment of shielding gases applying all-purpose supports and clamps.
4. Dying is carried out within a closed production cycle in compliance with all the customer’s requirements regarding the degree of fire resistance of the bearing structures. Preparation of the surface is carried out with the help of a sandblast machine. Application of lacquer coverings is carried out in compliance with GOST. Control of the applied covering quality is carried out in 3 stages: visual control, adhesion check and the covering thickness check.
5. Installation and assembly works are carried out with the help of modern highly efficient electric instruments.
6. Tests are carried out by highly qualified experts from a certified testing laboratory applying the fleet of modern equipment.
7. Package in case of PTS transportation for the distance of more than 200 km is made of PVC film of high strength and wearing resistance.

Quality Control

The plant has an implemented system of quality and business processes management.
The products quality control received from supplier enterprises (PIP (Purchased Integrated Parts), metal-roll, lacquer and paint materials) is carried out in accordance with the plant-accepted check lists depending on the type of components and the way of their receipt.

Certification Documents Check

At each stage of production the contractors having completed their operations and making sure they have been executed correctly prove this attaching their personal mark to corresponding columns of the Assembly Certificate and photo recording. The photos of carrying out of the operations and of the ready-made products are stored in the information system of the enterprise all time during the facility use.

Accompanying Processes

In order to provide for the production rhythm as one of the factors of efficiency increase the enterprise has the following processes localized and provided with resources:

  • Development of construction and technological documents
  • Planning
  • Dispatch
  • Equipment service
  • Technical control
  • Logistics
  • Warehousing

Active promotion of Keizen instruments allows to build up within the framework of the value creation flow not only constant improvements aimed at the increase of labour productivity, but also to provide the built-in quality at all production processes separation stages adding to instrumental technical control.

Metal Coverings

Development of metal PTS is based on project solutions and typical modules that enable to apply the design technology to archetypes. This provides minimum period of the development, quality and maximum satisfaction of the customer’s needs. Construction of the metal modules has an antivandal solution corresponding to the requirements of the most capricious customers. Life time of the metal covering comprises no less than 30 years

Concrete Coverings

Peculiarities of the production technology of concrete coverings enable to produce them all the year round. Constant warehouse stock of typical products is kept. If the order for products with special individual technical requirements is received, the production period of the substation covering from the moment of forming till the handover to the customer comprises 30 calendar days. The guarantee of high technologies, quality and reliability of the production process of the products is use of the equipment of German SMS Company. The casting equipment fleet includes 4 forming units: a wall block, a roof panel, a cable storey and a tilting device.

The products are manufactured out of the high-quality material – concrete material of М400 make with a double reinforcement providing for high strength, reliability and long endurance. When forming, the concrete samples are always cast. Correspondence of the ready-for-sale strength of the product to norms is controlled in a laboratory and proved by quality certificates.

An important stage in manufacturing of the concrete substations is a forming stage. This process takes place under control of the heating system in the automated mode. During one day and night the product is kept under temperature of 600С surely providing for reaching the necessary strength. This enables to reduce the term of the products manufacturing to 30 days and is a big advantage in comparison to other manufacturers’ products.

The life time of concrete coverings is more than 50 years.

One of main NIPOM advantages is individual approach to each customer. The Company is ready to offer any configuration variants of the products; if necessary the substations may be modified in accordance with specific requirements. NIPOM has its own typical projects worked out by the engineering center experts.

Delivery and Installation On Site

NIPOM provides for the possibility of delivery to any region of the country, and thanks to the use of modern loading equipment it carries out high quality unloading of products.

In the course of PTS transportation to the distance of more than 200 km the products are packed into PVC film having high strength and wearing resistance.

On site NIPOM experts carry out high quality installation of transformation substations, as well as render installation and launch service on a turnkey basis.

Service

In order to ensure maximum comfort of our customers the enterprise has a service department which can help with a technical assistance to our customers both at a distance and with a trip to the site. Experts of this department undergo periodical training both in external training centers and inside of the enterprise.